2004 CHRYSLER VOYAGER Block motor

Description N´m Ft. Lbs. In. Lbs.
A/C Expansion Valve
Screws11 ± 9 7
A/C-Heater Control
Screws2±17
Blend Door Actuator
Screws2±17
Blower Motor Screws 2 ± 17
Blower Motor Power
Module Screws (ATC)2±17
Blower Motor Resistor
Block Screws (MTC)2±17
Center Bezel Outlet
Screws2±17
Distribution Housing
Screws2±17
Discharge Line to
Compressor Nut23 17 ±
Discharge Line to
Condenser Nut23 17 ±
Front Fascia Screws 6 ± 53
Front Fascia Grille Insert
Screws2±17
Heater Core Mounting
Plate Screws2±17
Heater Core Sealing Plate
Screws3±26
Hood Latch Screws 14 ± 123
HVAC Housing Bracket
Bolt3±26
HVAC Housing Mounting
Nuts7±62
HVAC Housing Mounting
Bolts4±35
Liquid Line to Condenser
Nut23 17 ±
Liquid Line to Receiver/
drier Bolt11 ± 9 7
Lower Air inlet Housing
Screws2±17
Mode Door Actuator
Screws2±17
Quarter Trim Panel
Attaching Bracket Screws2±17
Rear Blower Motor
Screws2±17
Rear Blower Motor Power
Module Screws (ATC)2±17
24 - 12 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

Description N´m Ft. Lbs. In. Lbs.
Rear Blower Motor
Resistor Block Screws
(MTC)2±17
Rear Capture Plate Screw 2 ± 17
Rear Evaporator Line Seal
Plate to Rear Expansion
Valve Nut23 17 ±
Rear Expansion Valve
Bracket Nut23 17 ±
Rear Expansion Valve
Bracket Screws2±17
Rear Expansion Valve to
Rear Evaporator Screws11 ± 9 7
Rear Floor Heat Duct
Screws2±17
Rear HVAC Housing
Screws2±17
Rear HVAC Housing
Mounting Screws11 ± 9 7
Rear HVAC Housing Stud
Nuts9±80
Rear Mode Door Actuator
Screws2±17
Receiver/drier Bracket
Nuts10 ± 89
Recirculation Door
Actuator Screws2±17
Refrigerant Lines to
Expansion Valve Nut23 17 ±
Suction Line to
Compressor Nut23 17 ±
Cabin Heater Air Intake
Pipe Screws7±62
Cabin Heater M6 Bolts 7 ± 62
Cabin Heater M8 Bolts 23 17 ±
Cabin Heater Seat Hex
Nut60 44 ±
Underbody Liquid Line
Fitting23 17 ±
Underbody Refrigerant
Line Sealing Plate Screw23 17 ±
Underbody Suction Line
Fitting23 17 ±
Upper Air Inlet Housing
Screws2±17
RSHEATING & AIR CONDITIONING24-13
HEATING & AIR CONDITIONING (Continued)

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........15
REMOVAL.............................16
INSPECTION..........................17
INSTALLATION.........................17
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
A/C HEATER CONTROL
DESCRIPTION.........................20
STANDARD PROCEDURE - A/C-HEATER
CONTROL CALIBRATION...............20
REMOVAL.............................21
INSTALLATION.........................21
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................22
REMOVAL.............................22
INSTALLATION.........................22
BLEND DOOR ACTUATOR
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
BLOWER MOTOR RELAY
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................25
INSTALLATION.........................25
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................26OPERATION...........................26
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK..............26
REMOVAL.............................26
INSTALLATION.........................27
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................27
OPERATION...........................28
REMOVAL
REMOVAL - AUTOMATIC TEMPERATURE
CONTROL (ATC)......................28
REMOVAL - MANUAL TEMPERATURE
CONTROL (MTC)......................29
INSTALLATION
INSTALLATION - AUTOMATIC
TEMPERATURE CONTROL (ATC).........29
INSTALLATION - MANUAL TEMPERATURE
CONTROL (MTC)......................29
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................29
OPERATION...........................29
MODE DOOR ACTUATOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................31
POWER MODULE - BLOWER MOTOR
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................32
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................33
INSTALLATION.........................33
24 - 14 CONTROLS - FRONTRS

BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C system.
Models equipped with the optional Automatic Tem-
perature Control (ATC) system use a blower power
module, instead of the blower motor resistor block
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/POWER MODULE - DESCRIPTION).
The blower motor resistor block is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The resistor
block consists of a molded plastic mounting plate
with two integral connector receptacles. Concealed
behind the mounting plate are four coiled resistor
wires contained within a protective stamped steel
cage. The blower motor resistor block is accessed for
service by removing the glove box from the instru-
ment panel.
OPERATION
The blower motor resistor block is connected to the
vehicle electrical system through a dedicated take
out and connector of the instrument panel wire har-
ness. A second connector receptacle receives the pig-
tail wire connector from the blower motor. The
blower motor resistor has multiple resistor wires,
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 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 resis-
tor wires, increasing the blower motor speed.
The blower motor resistor cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR BLOCK
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block.
(4) Check for continuity between each of the
blower motor switch input terminals of the resistor
and the resistor output terminal. In each case there
should be continuity. If OK, repair the wire harness
circuits between the blower motor switch and the
blower motor resistor, blower motor or blower motor
relay as required. If not OK, replace the faulty
blower motor resistor block.
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.
WARNING: THE BLOWER MOTOR RESISTOR
BLOCK MAY GET VERY HOT DURING NORMAL
OPERATION. IF THE BLOWER MOTOR WAS
TURNED ON PRIOR TO SERVICING THE BLOWER
MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES
TO ALLOW THE BLOWER MOTOR RESISTORS TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
24 - 26 CONTROLS - FRONTRS

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) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block (Fig. 14).
(4) Remove the two screws that secure the blower
motor resistor block to the HVAC housing.
(5) Remove the resistor block from the HVAC
housing.
INSTALLATION
(1) Position the blower motor resistor block into
the HVAC housing.
(2) Install the two screws that secure the blower
motor resistor block to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the resistor
block.
(4) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
NOTE: The following applies to RS models only. RG
models use an expansion valve mounted evapora-
tor temperature sensor for both manual and auto-
matic temperature control systems due to A/C-
heater control calibration requirements.
The evaporator temperature sensor used for the
manual temperature control (MTC) system is
installed on the top of the HVAC housing behind the
instrument panel and measures the air temperature
downstream of the evaporator (Fig. 15). The sensor is
an electrical thermistor in a plastic housing that is
inserted into the HVAC housing. Two terminals
within the molded plastic connector receptacle on the
sensor connect it to the vehicle electrical system
through a take out and connector of the HVAC wire
harness.
The evaporator temperature sensor used for the
automatic temperature control (ATC) system is
installed on the top of the expansion valve in the
right rear corner of the engine compartment and
measures the temperature of the evaporator coils
(Fig. 16). The sensor has a small probe that is
Fig. 14 Blower Motor Resistor Block - Typical
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE HARNESS
6 - HVAC HOUSING
Fig. 15 Evaporator Temperature Sensor - MTC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - HVAC HOUSING
3 - A/C EVAPORATOR
RSCONTROLS - FRONT24-27
BLOWER MOTOR RESISTOR BLOCK (Continued)

(5) Remove the mode door actuator from the distri-
bution housing.
INSTALLATION
(1) Position the mode door actuator onto the HVAC
distribution housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the mode door linkage.
(2) Install the two screws that secure the mode
door actuator to the distribution housing. Tighten the
screws to 2 N´m (17 in. lbs.).
(3) Connect the wire harness connector to the
mode door actuator.
(4) Install the silencer under the driver side end of
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL SILENCER -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Perform the A/C-heater 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 - BLOWER
MOTOR
DESCRIPTION
A blower motor power module is used on this
model when it is equipped with the optional Auto-
matic Temperature Control (ATC) system. Modelsequipped 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 blower motor power module is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The module
consists of a molded plastic mounting plate with two
integral connector receptacles. Concealed behind the
mounting plate is the power module electronic cir-
cuitry and a large finned, heat sink. The blower
motor power module is accessed for service by remov-
ing the glove box from the instrument panel.
OPERATION
The blower motor power module is connected to the
vehicle electrical system through a dedicated lead
and connector from the instrument panel wire har-
ness. A second connector receptacle receives a wire
lead connector from the blower motor. The blower
motor power module allows the microprocessor-based
Automatic Temperature Control (ATC) heater-A/C
control module to calculate and provide infinitely
variable blower motor speeds based upon either man-
ual blower switch input or the ATC programming
using a Pulse Width Modulated (PWM) circuit strat-
egy. The PWM voltage is applied to a comparator cir-
cuit 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 motor power module is diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures.
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.
Fig. 20 Mode Door Actuator - LHD Shown, RHD
Typical
1 - WIRE HARNESS CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
RSCONTROLS - FRONT24-31
MODE DOOR ACTUATOR (Continued)

CONTROLS - REAR
TABLE OF CONTENTS
page page
A/C-HEATER CONTROL
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................35
BLEND DOOR ACTUATOR
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................36
INSTALLATION.........................36
BLOWER MOTOR RELAY
DESCRIPTION.........................37
OPERATION...........................37
REMOVAL.............................38
INSTALLATION.........................38
BLOWER MOTOR RESISTOR
DESCRIPTION.........................38OPERATION...........................38
DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR RESISTOR BLOCK..............38
REMOVAL.............................39
INSTALLATION.........................39
MODE DOOR ACTUATOR - REAR
DESCRIPTION.........................39
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................40
POWER MODULE - REAR BLOWER MOTOR
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................41
INSTALLATION.........................42
A/C-HEATER CONTROL
DESCRIPTION
The rear heater-A/C system is controlled by rotary-
type blower motor and temperature controls, cen-
trally mounted in the headliner. The rear A/C-heater
control allows selection of three blower motor speeds
and an Off position when the center knob on the
front A/C-heater control is set to the Rear position,
otherwise the front unit controls both front and rear
heater-A/C operation.
OPERATION
With the rear A/C-heater control active, tempera-
ture selection dictates the air distribution mode (floor
or overhead air) of the rear unit. A cool temperature
setting directs flow to the overhead outlets and a
warm temperature setting to the floor. Refer to Body
Diagnostic Procedures for further diagnostic informa-
tion.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick or another suitable wide flat
bladed tool, gently pry the top edge of the rear A/C-
heater control bezel away from the headliner far
enough to release the two snap clip retainers (Fig. 1).(3) Pull the rear A/C-heater control rearward far
enough to access the headliner wire harness connec-
tor on the back of the control.
(4) Disconnect the wire harness connector from the
rear A/C-heater control.
(5) Remove the rear A/C-heater control from the
headliner.
Fig. 1 Rear A/C-Heater Control
1 - TRIM STICK
2 - BEZEL
3 - REAR A/C-HEATER CONTROL
4 - HEADLINER
24 - 34 CONTROLS - REARRS

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)