2004 CHRYSLER VOYAGER service

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
from the recirculation door actuator (Fig. 22).
(4) Remove the two screws that secure the recircu-
lation door actuator to the air inlet housing.
(5) Remove the recirculation door actuator from
the air inlet housing.
INSTALLATION
(1) Position the recirculation door actuator onto
the air intake housing. If necessary, rotate the actua-
tor slightly to align the splines on the actuator out-
put shaft with those in the recirculation air door.
(2) Install the two screws that secure the recircu-
lation door actuator to the air intake housing.
Tighten the screws to 2 N´m (17 in. lbs.).(3) Connect the HVAC wire harness connector to
the recirculation door actuator.
(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. 22 Recirculation Door Actuator - LHD Shown,
RHD Typical
1 - AIR INLET HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER HVAC HOUSING
RSCONTROLS - FRONT24-33
RECIRCULATION DOOR ACTUATOR (Continued)

Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unlatch and remove the cover from the Inte-
grated Power Module (IPM) (Fig. 5).
(3) See the fuse and relay layout map molded into
the inner surface of the IPM cover for rear blower
motor relay identification and location.
(4) Remove the rear blower motor relay from the
IPM.
INSTALLATION
(1) See the fuse and relay layout map molded into
the inner surface of the Integrated Power Module
(IPM) cover for rear blower motor relay identification
and location.
(2) Position the rear blower motor relay to the
proper receptacle in the IPM.
(3) Align the rear blower motor relay terminals
with the terminal cavities in the IPM relay recepta-
cle.
(4) Push down firmly on the rear blower motor
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.
(6) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
DESCRIPTION
A rear blower motor resistor is used on this model
when it is equipped with the manual heater-A/C sys-
tem. Models equipped with the optional Automatic
Temperature Control (ATC) system use a rear blower
motor power module, instead of the blower motor
resistor block (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/POWER MODULE -
DESCRIPTION). The rear blower motor resistor
block is mounted to the rear HVAC housing, directly
above the expansion valve. The resistor block con-
sists of a molded plastic mounting plate with an inte-
gral connector receptacle. Concealed behind the
mounting plate is an electrical circuit board with two
resistors and a thermal fuse. The rear blower motor
resistor block is accessed for service by removing the
right quarter and D-pillar trim panels.
OPERATION
The rear blower motor resistor block is connected
to the vehicle electrical system through a dedicated
take out and connector of the rear HVAC wire har-
ness. The blower motor resistor has an electrical cir-
cuit board with two resistors, 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 system directs the
ground path for the rear blower motor through the
correct resistor to obtain the selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through both resistors. Each higher speed selected
with the blower motor switch applies the blower
motor ground path through fewer of the resistors,
increasing the blower motor speed. When the blower
motor switch is in the highest speed position, the
blower motor resistors are bypassed and the blower
motor receives a direct path to ground through the
blower motor switch.
The rear blower motor resistor block cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR RESISTOR BLOCK
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
Fig. 5 Integrated Power Module - Typical
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
24 - 38 CONTROLS - REARRS
BLOWER MOTOR RELAY (Continued)

(6) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(7) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N´m (97 in. lbs.).
(8) Install the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel. Tighten the screws to 2 N´m (17 in.
lbs.).
(9) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(10) Reconnect the battery negative cable.
(11) Perform the heater-A/C control calibration
procedure (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION).
POWER MODULE - REAR
BLOWER MOTOR
DESCRIPTION
A rear blower motor power module is used on this
model when it is equipped with the optional Auto-
matic Temperature Control (ATC) system. Models
equipped with the standard manual heater-A/C sys-
tem use a blower motor resistor block , instead of the
blower motor power module (Refer to 24 - HEATING
& AIR CONDITIONING/CONTROLS/BLOWER
MOTOR RESISTOR BLOCK - DESCRIPTION).
The rear blower motor power module is installed in
the back of the rear HVAC housing, directly above
the expansion valve. The module 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
power module is accessed for service by removing the
right quarter and D-pillar trim panels.
OPERATION
The rear blower motor power module is connected
to the vehicle electrical system through a dedicated
take out and connector of the rear HVAC wire har-
ness. A second connector receptacle receives the pig-
tail wire connector from the rear blower motor. The
rear blower motor power module allows the micropro-
cessor-based Automatic 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 pro-
gramming 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
rear blower motor relay to change or maintain the
desired blower speed. The rear blower motor power
module is diagnosed using a DRBIIItscan tool. Refer
to Body Diagnostic Procedures.
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) Disconnect the rear HVAC wire harness con-
nector from the rear blower motor power module
(Fig. 8).
(4) Disconnect the rear blower motor pigtail wire
connector from the rear blower motor power module.
(5) Remove the two screws that secure the rear
blower motor power module to the rear HVAC hous-
ing.
(6) Remove the rear blower motor power module
from the rear HVAC housing.
Fig. 8 Rear Blower Motor Power Module
1 - REAR HVAC HOUSING
2 - SCREW (2)
3 - D-PILLAR
4 - REAR BLOWER MOTOR PIGTAIL WIRE
5 - REAR HVAC WIRE HARNESS
6 - EXPANSION VALVE
7 - REAR BLOWER MOTOR POWER MODULE
RSCONTROLS - REAR24-41
MODE DOOR ACTUATOR - REAR (Continued)

(5) Pull the air filter straight down and out of the
HVAC housing (Fig. 2).
INSTALLATION
(1) Note the ªAirflowº directional arrow imprinted
on the foam seal around the frame of the air filter.
This arrow should always be oriented towards the
center of the vehicle.
(2) With the air filter ªAirflowº arrow properly ori-
ented, carefully slide the filter fully upward into the
HVAC housing through the air filter opening.
(3) With the latch still positioned against its
opened stop, reinstall the air filter door onto the
lower HVAC housing air filter opening.
(4) Slide the air filter door latch toward the front
of the vehicle until it hits the closed stop on the door.
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the front HVAC housing through one or a
combination of the four main housing outlets: defrost,
demist, panel, or floor. Once the conditioned air exits
the unit housing, it is directed through molded plas-
tic ducts to the various outlets in the vehicle interior.
These outlets and their locations are as follows:
²Defroster Outlet- A single, centrally mounted
outlet delivers air for defrosting the large windshield.
Because outlet vanes are not needed to direct flow, a
simple, integral grid is molded into the center of the
instrument panel top cover to prevent objects from
falling into the duct. If the defroster outlet is faultyor 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) system, 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 HVAC distribution hous-
ing.
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 HVAC 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 with
the optional automatic temperature control (ATC)
Fig. 2 Air Filter Door - Typical
1 - AIR FILTER DOOR
2-LATCH
3 - CLOSED STOP
4 - LOWER HVAC HOUSING
5 - OPENED STOP
24 - 44 DISTRIBUTION - FRONTRS
AIR FILTER (Continued)

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 negative battery
cable.
(2) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(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 - INSTRUMENT PANEL OUTLET
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
instrument panel outlet away from the instrument
panel top pad until the snap features on the outlet
are released (Fig. 5).
(2) Remove the instrument panel outlet from the
panel duct opening in the instrument panel top pad.
INSTALLATION
INSTALLATION - CENTER BEZEL OUTLETS
(1) Position the center bezel outlets and housing
onto the center bezel as a unit.
Fig. 3 Center Air Outlets
1 - CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - SCREW (3)
4 - INSTRUMENT PANEL SWITCH BANK
5 - CONNECTOR (ATC ONLY)
6 - JUMPER HARHESS (ATC ONLY)
Fig. 4 Demister Outlet
1 - DEMISTER OUTLET
2 - INSTRUMENT PANEL TOP PAD
3 - TRIM STICK
RSDISTRIBUTION - FRONT24-45
AIR OUTLETS (Continued)

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
HVAC housing by spinning the blower wheel within
the housing at the selected speed or, in the ATC sys-
tem, 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.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 10 - 40 ampere) in the
Integrated 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 A/C-heater 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, check the front blower motor relay.
(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 block (Manual
Temperature Control) or the front blower motor
power module (Automatic Temperature Control) from
the resistor or module connector receptacle. Recon-
nect the battery negative cable. Turn the ignition
switch to the On position. Be certain that the A/C-
heater 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 connec-
tor for the front blower motor resistor block (MTC) orthe front blower motor 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 block (MTC) or the front
blower motor 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 diagno-
sis of the front blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/BLOWER MOTOR RESISTOR - DIAGNO-
SIS AND TESTING). If OK with ATC, use a DRBIII
scan tool to diagnose the front blower motor power
module. Refer to Body 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 for basic checks of the blower motor when a
vibration or noise is present (Fig. 7).
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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The blower motor is located on the passen-
ger side of the vehicle under the instrument panel.
The blower motor can be removed from the vehicle
without having to remove the HVAC housing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the passenger side door sill plate and
cowl panel.
(3) Pull back the carpet to access the front lower
air intake screw.
RSDISTRIBUTION - FRONT24-47
BLOWER MOTOR (Continued)

(6) Install the four screws (from the bottom) that
secure the lower air inlet housing to the lower HVAC
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(7) Install the one screw (from the top) that
secures the lower air inlet housing to the upper air
intake housing. Tighten the screws to 2 N´m (17 in.
lbs.).
(8) Connect the blower motor pigtail harness con-
nector to the blower motor resistor block or power
module, depending how vehicle is equipped.
(9) Install the recirculation door actuator (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - INSTALLA-
TION).
(10) Install the recirculation door actuator wire
harness lead into the routing clip on the lower air
inlet housing.
(11) Reinstall the carpet.
(12) Install the passenger side door sill plate and
cowl panel.
(13) Reconnect the battery negative cable.
(14) Perform the heater-A/C control calibration
procedure (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION).
DEFROSTER DUCT
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 instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.(4) Remove the fasteners that secure the defroster
duct to the instrument panel armature.
(5) Remove the defroster duct from the instrument
panel.
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 defroster duct to the instrument
panel.
(2) Install the fasteners that secure the defroster
duct to the instrument panel armature.
(3) Reinstall the instrument panel in the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 11).
(3) Pull the center floor distribution duct rearward
far enough to disengage it from the floor outlet of the
HVAC housing.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required.
(2) Slide the center floor distribution duct under
the instrument panel center stack far enough to
engage it to the floor outlet of the HVAC housing.
24 - 50 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)

(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
REMOVAL
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) AND (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
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) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the windshield wiper module from the
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(5) Disconnect the liquid line and suction line from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(6) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(7) On LHD models, remove the one bolt that
secures the HVAC housing to the dash panel (Fig.
12).
(8) Remove the three nuts that secure the HVAC
housing to the dash panel.
(9) Remove the instrument panel from the passen-
ger compartment (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(10) Remove the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
REMOVAL).
(11) Remove the bolt or bolts (depending on appli-
cation) that secure the HVAC housing to the passen-
ger compartment side of the dash panel (Fig. 13) or
(Fig. 14).
(12) Pull the HVAC housing rearward far enough
for the mounting studs to clear the dash panel and
remove the housing from the passenger compart-
ment.
DISSASEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).
Fig. 11 Floor Distribution Ducts - LHD Shown, RHD
Typical
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-51
FLOOR DISTRIBUTION DUCTS (Continued)