2004 CHRYSLER VOYAGER Block motor

(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the rear HVAC wire harness con-
nector from the rear blower motor resistor.
(3) Check for continuity between each of the
blower motor switch input terminals of the blower
motor resistor and the resistor output terminal. In
each case there should be continuity. If OK, repair
the 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: THE REAR 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.
CAUTION: Do not operate the blower motor with the
blower motor resistor block removed from the cir-
cuit. Failure to take this precaution can result in
vehicle damage.
(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 blower motor resistor block (Fig. 6).
(4) Remove the two screws that secure the blower
motor resistor block to the rear HVAC housing.
(5) Remove the rear blower motor resistor block
from the rear HVAC housing.
INSTALLATION
(1) Position the rear blower motor resistor block
into the rear HVAC housing.
(2) Install the two screws that secure the rear
blower motor resistor block to the rear HVAC hous-
ing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Connect the rear HVAC wire harness connector
to the rear blower motor resistor block.
(4) 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).
(5) Reconnect the battery negative cable.
MODE DOOR ACTUATOR -
REAR
DESCRIPTION
The rear mode door actuator is a reversible, 12-volt
Direct Current (DC), servo motor. The mode door actua-
tor is located on the outboard side of the rear HVAC
housing, above the blend door actuator. The mode door
actuator is mechanically connected to the mode door.
The rear mode door actuator is interchangeable with
the actuator for the blend door. Each actuator is con-
tained within an identical black molded plastic housing
with an integral wire connector receptacle. Two integral
mounting tabs allow the actuator to be secured with
two screws to the rear HVAC housing. Each actuator
also has an identical output shaft with splines that con-
nects it to the pivot or linkage of the proper door. The
rear mode door actuator does not require mechanical
indexing to the mode door pivot, as it is electronically
calibrated by the front heater-A/C control module.
Fig. 6 Rear Blower Motor Resistor Block
1 - REAR HVAC HOUSING
2 - D-PILLAR
3 - BLOWER PIGTAIL WIRE
4 - CONNECTOR
5 - EXPANSION VALVE
6 - SCREW (2)
7 - BLOWER MOTOR RESISTOR BLOCK
RSCONTROLS - REAR24-39
BLOWER MOTOR RESISTOR (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)

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)

(4) Remove the recirculation door actuator (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/RECIRCULATION DOOR ACTUATOR -
REMOVAL).
(5) Disconnect the recirculation door actuator wire
harness lead from the routing clip on the lower air
inlet housing and position the wire harness aside.
(6) Disconnect the blower motor pigtail harness
connector from the blower motor resistor block or
power module, depending how vehicle is equipped.
(7) Remove the one screw (from the top) that
secures the lower air inlet housing to the upper air
inlet housing (Fig. 8).
(8) Remove the four screws (from the bottom) that
secure the lower air inlet housing to the lower HVAC
housing and upper air inlet housing.
(9) Push the rubber grommet on the blower motor
pigtail through the hole in the lower air inlet housing
(Fig. 9).
(10) Feed the blower motor pigtail and electrical
connector through the grommet hole in the lower air
inlet housing.
(11) Relocate the recirculation air door as neces-
sary to access and remove the three screws that
secure the blower motor to the lower half of the
HVAC housing.
(12) Gently flex the recirculation air door far
enough to remove the blower motor and blower wheel
from the housing.
(13) Remove the blower motor from the housing.
Note the position of the blower motor mounting tabs
(Fig. 10).
INSTALLATION
(1) Position the blower motor to the HVAC hous-
ing. Align the blower motor mounting tabs to the
proper tabs on the housing.
(2) Gently flex the recirculation air door far
enough to position the blower motor and wheel into
the lower half of the HVAC housing.
(3) Install the three screws that secure the blower
motor to the lower half of the HVAC housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(4) Feed the blower motor pigtail and electrical
connector through the grommet hole in the lower air
inlet housing and seat the rubber grommet.
(5) Position the recirculation door into the lower
air inlet housing.
Fig. 8 Air Inlet Housing - LDH Shown, RHD Typical
1 - HVAC HOUSING
2 - UPPER AIR INLET HOUSING
3 - RECIRCULATION AIR DOOR
4 - BLOWER MOTOR AND WHEEL
Fig. 9 Blower Motor Grommet - Typical
1 - BLOWER MOTOR PIGTAIL WIRE GROMMET
Fig. 10 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-49
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)

DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR
BLOWER MOTOR INOPERATIVE
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 12 - 25 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 rear A/C-heater 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, check the rear blower motor relay.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector
from the rear blower motor resistor block (Manual
Temperature Control) or the rear blower motor power
module (Automatic Temperature Control). Reconnect
the battery negative cable. Turn the ignition switch
to the On position. Be certain that the rear A/C-
heater 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 connec-
tor for the rear blower motor resistor block (MTC) or
the rear 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 rear blower motor pigtail wire connec-
tor from the rear HVAC wire harness (MTC) or the
rear blower power module (ATC). Use jumper wires
to connect a battery and ground feeds to the blower
motor pigtail wire connector. The rear blower motor
should operate. If OK with MTC, proceed to diagno-
sis of the rear blower motor resistor block (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 motor power module.
Refer to the appropriate diagnostic information. 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 for basic checks of the blower motor when a
vibration or noise is present (Fig. 3).
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).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control sys-
tem, the blower motor pigtail wire is connected to a
take out and connector of the rear HVAC wire har-
ness. With the Automatic Temperature Control sys-
tem , the blower pigtail wire is connected to a
receptacle on the blower motor power module.
(3) Remove the three screws that secure the rear
blower motor to the outboard side of the rear HVAC
housing (Fig. 4).
(4) Remove the rear blower motor from the rear
HVAC housing.
INSTALLATION
(1) Position the rear blower motor into the rear
HVAC housing.
(2) Install the three screws that secure the blower
motor to the rear HVAC housing. Tighten the screws
to 2 N´m (17 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control system
, the blower pigtail wire is connected to a take out
and connector of the rear HVAC wire harness. With
the Automatic Temperature Control system, the
blower pigtail wire is connected to a receptacle on
the blower motor power module.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

CHARGING PROCEDURE
CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrig-
erant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more infor-
mation.
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(2) A manifold gauge set and a R-134a refrigerant
recovery/recycling/charging station that meets SAE
Standard J2210 should still be connected to the
refrigerant system.
(3) Measure the proper amount of refrigerant and
heat it to 52É C (125É F) with the charging station.
See the operating instructions supplied by the equip-
ment manufacturer for proper use of this equipment.
(4) Open both the suction and discharge valves,
then open the charge valve to allow the heated
refrigerant to flow into the system.
(5) When the transfer of refrigerant has stopped,
close both the suction and discharge valves.
(6) If all of the refrigerant charge did not transfer
from the dispensing device, open all of the windows
in the vehicle and set the heater-air conditioner con-
trols so that the compressor is engaged and the
blower motor is operating at its lowest speed setting.
Run the engine at a steady high idle (about 1400
rpm). If the compressor will not engage, test the com-
pressor clutch control circuit and repair as required.
(7) Open the suction valve to allow the remaining
refrigerant to transfer to the refrigerant system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH PRESSURE) VALVE AT THIS TIME.
(8) Close the suction valve and test the system
performance. (Refer to 24 - HEATING & AIR CON-
DITIONING - STANDARD PROCEDURE - A/C PER-
FORMANCE TEST).
(9) Disconnect the charging station and manifold
gauge set from the refrigerant system service ports.
(10) Reinstall the caps onto the refrigerant system
service ports.
(11) Run the HVAC Control Cooldown test to ver-
ify proper operation(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).A/C COMPRESSOR
DESCRIPTION
DESCRIPTION - A/C COMPRESSOR
Vehicles equipped with the 2.5L diesel, 3.3L and
3.8L gasoline engines use the Denso 10S20 A/C com-
pressor. Vehicles equipped with the 2.4L gasoline
engine use the Denso 10S17 A/C compressor. Both
A/C compressors include an integral high pressure
relief valve. The A/C compressor is secured to a
mounting bracket on the 2.4L gasoline engine and
directly to the cylinder block on the 2.5L diesel, 3.3L
and 3.8L gasoline engines.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A high pressure relief valve is located on the rear
of the A/C compressor. This mechanical valve is
designed to vent refrigerant from the A/C system to
protect against damage to the compressor and other
system components, caused by condenser air flow
restriction or an overcharge of refrigerant.
OPERATION
OPERATION - A/C COMPRESSOR
The A/C compressor is driven by the engine
through an electric clutch, drive pulley and belt
arrangement. The compressor is lubricated by refrig-
erant oil that is circulated throughout the refrigerant
system with the refrigerant.
The compressor draws in low-pressure refrigerant
vapor from the evaporator through its suction port. It
then compresses the refrigerant into a high-pressure,
high-temperature refrigerant vapor. The compressor
pumps the high-pressure refrigerant vapor to the
condenser through the compressor discharge port.
The compressor cannot be repaired. If faulty or
damaged, the entire compressor assembly must be
replaced. The compressor clutch, pulley and clutch
coil are available for service.
OPERATION - HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents the system
when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes
when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
RSPLUMBING - FRONT24-73
PLUMBING - FRONT (Continued)

BLEEDING - STANDARD PROCEDURE,
BASE BRAKE......................5-7,5s-7
BLEEDING - STANDARD PROCEDURE,
MASTER CYLINDER...............5-35,5s-34
BLEND DOOR ACTUATOR -
DESCRIPTION..................24-23,24-35
BLEND DOOR ACTUATOR -
INSTALLATION..................24-23,24-36
BLEND DOOR ACTUATOR - OPERATION . . 24-23,
24-35
BLEND DOOR ACTUATOR - REMOVAL....24-23,
24-36
BLOCK - CLEANING, ENGINE.......9-112,9-36
BLOCK - DESCRIPTION, BLOWER
MOTOR RESISTOR...................24-26
BLOCK - DESCRIPTION, ENGINE.....9-112,9-35
BLOCK - DESCRIPTION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - DIAGNOSIS AND TESTING,
BLOWER MOTOR RESISTOR............24-26
BLOCK - DIAGNOSIS AND TESTING,
REAR BLOWER MOTOR RESISTOR......24-38
BLOCK - INSPECTION, ENGINE......9-112,9-36
BLOCK - INSTALLATION, BLOWER
MOTOR RESISTOR...................24-27
BLOCK - INSTALLATION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - OPERATION, BLOWER MOTOR
RESISTOR..........................24-26
BLOCK - OPERATION, NON-ABS
JUNCTION......................5-33,5s-32
BLOCK - REMOVAL, BLOWER MOTOR
RESISTOR...........................24-26
BLOCK - REMOVAL, NON-ABS JUNCTION . . 5-33,
5s-32
BLOCK HEATER - DESCRIPTION, ENGINE . . . 7-20
BLOCK HEATER - INSTALLATION,
ENGINE.............................7-20
BLOCK HEATER - OPERATION, ENGINE....7-20
BLOCK HEATER - REMOVAL, ENGINE......7-20
BLOCK HEATER TESTING - DIAGNOSIS
AND TESTING, ENGINE.................7-20
BLOCKER LATCH - INSTALLATION, FUEL
FILL DOOR.........................23-53
BLOCKER LATCH - REMOVAL, FUEL FILL
DOOR.............................23-53
BLOCKER LATCH STRIKER -
INSTALLATION, FUEL FILL DOOR........23-53
BLOCKER LATCH STRIKER - REMOVAL,
FUEL FILL DOOR.....................23-53
BLOCKER LOCKOUT LINK -
INSTALLATION, FUEL FILL DOOR........23-54
BLOCKER LOCKOUT LINK - REMOVAL,
FUEL FILL DOOR.....................23-53
BLOWER MOTOR - DESCRIPTION . . 24-46,24-57
BLOWER MOTOR - DESCRIPTION,
POWER MODULE....................24-31
BLOWER MOTOR - DESCRIPTION,
POWER MODULE - REAR..............24-41
BLOWER MOTOR - DIAGNOSIS AND
TESTING...........................24-47
BLOWER MOTOR - DIAGNOSIS AND
TESTING, REAR......................24-58
BLOWER MOTOR - INSTALLATION . . 24-49,24-58
BLOWER MOTOR - INSTALLATION,
POWER MODULE....................24-32
BLOWER MOTOR - INSTALLATION,
POWER MODULE - REAR..............24-42
BLOWER MOTOR - OPERATION....24-46,24-57
BLOWER MOTOR - OPERATION, POWER
MODULE...........................24-31
BLOWER MOTOR - OPERATION, POWER
MODULE - REAR.....................24-41
BLOWER MOTOR - REMOVAL......24-47,24-58
BLOWER MOTOR - REMOVAL, POWER
MODULE...........................24-31
BLOWER MOTOR - REMOVAL, POWER
MODULE - REAR.....................24-41
BLOWER MOTOR RELAY - DESCRIPTION
. 24-24,
24-37
BLOWER MOTOR RELAY -
INSTALLATION
..................24-25,24-38
BLOWER MOTOR RELAY - OPERATION
. . . 24-24,
24-37
BLOWER MOTOR RELAY - REMOVAL
....24-25,
24-38
BLOWER MOTOR RESISTOR -
DESCRIPTION
.......................24-38BLOWER MOTOR RESISTOR -
INSTALLATION.......................24-39
BLOWER MOTOR RESISTOR -
OPERATION.........................24-38
BLOWER MOTOR RESISTOR - REMOVAL . . 24-39
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION.......................24-26
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING.............24-26
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING, REAR........24-38
BLOWER MOTOR RESISTOR BLOCK -
INSTALLATION.......................24-27
BLOWER MOTOR RESISTOR BLOCK -
OPERATION.........................24-26
BLOWER MOTOR RESISTOR BLOCK -
REMOVAL..........................24-26
BODY - ASSEMBLY, VALVE.....21-257,21s-159,
21s-212
BODY - DESCRIPTION, THROTTLE.......14-35
BODY - DESCRIPTION, VALVE . . . 21-250,21s-152
BODY - DISASSEMBLY, VALVE . . 21-252,21s-155,
21s-208
BODY - INSTALLATION, THROTTLE.......14-35
BODY - INSTALLATION, VALVE . . 21-262,21s-164,
21s-217
BODY - OPERATION, THROTTLE.........14-35
BODY - OPERATION, VALVE....21-250,21s-152
BODY - REMOVAL, THROTTLE..........14-35
BODY - REMOVAL, VALVE.....21-251,21s-153,
21s-206
BODY AND CABLE - DESCRIPTION,
ANTENNA...........................8A-4
BODY AND CABLE - DIAGNOSIS AND
TESTING, ANTENNA...................8A-4
BODY AND CABLE - INSTALLATION,
ANTENNA...........................8A-6
BODY AND CABLE - OPERATION,
ANTENNA...........................8A-4
BODY AND CABLE - REMOVAL,
ANTENNA...........................8A-5
BODY CODE PLATE - DESCRIPTION.....Intro.-1
BODY CONTROL MODULE -
DESCRIPTION........................8s-1
BODY CONTROL MODULE -
DESCRIPTION........................8E-3
BODY CONTROL MODULE -
INSTALLATION........................8s-3
BODY CONTROL MODULE -
INSTALLATION........................8E-5
BODY CONTROL MODULE - OPERATION . . . 8s-1
BODY CONTROL MODULE - OPERATION . . . 8E-3
BODY CONTROL MODULE - REMOVAL.....8s-3
BODY CONTROL MODULE - REMOVAL.....8E-4
BODY LUBRICATION, SPECIFICATIONS....23-12
BODY OPENING DIMENSIONS -
SPECIFICATIONS....................23-127
BODY PANEL REPAIR - STANDARD
PROCEDURE, PLASTIC.................23-3
BODY SEALING LOCATIONS -
SPECIFICATIONS....................23-130
BODY SIDE MOLDINGS - INSTALLATION . . 23-46
BODY SIDE MOLDINGS - REMOVAL......23-45
BODY, SPECIAL TOOLS................23-13
BOLSTER - INSTALLATION, QUARTER
TRIM..............................23-79
BOLSTER - REMOVAL, QUARTER TRIM . . . 23-79
BOOSTER - DESCRIPTION, POWER
BRAKE.........................5-40,5s-43
BOOSTER - DIAGNOSIS AND TESTING,
POWER BRAKE..................5-41,5s-44
BOOSTER - OPERATION, POWER BRAKE . . 5-41,
5s-44
BOOT - INNER - INSTALLATION, CV........3-6
BOOT - INNER - REMOVAL, CV...........3-6
BOOT - INNER/OUTER - INSTALLATION,
CV .................................3-17
BOOT - INNER/OUTER - REMOVAL, CV....3-15
BOOT - INSTALLATION, GEARSHIFT......21-73
BOOT - OUTER - INSTALLATION, CV......3-10
BOOT - OUTER - REMOVAL, CV..........3-10
BOOT - REMOVAL, GEARSHIFT
..........21-72
BORE FITTING - STANDARD
PROCEDURE, PISTON TO CYLINDER
......9-42
BORE HONING - STANDARD
PROCEDURE, CYLINDER
...........9-112,9-35
BOX - INSTALLATION, GLOVE
...........23-64
BOX - REMOVAL, GLOVE
..............23-64BOX LAMP SWITCH - INSTALLATION,
GLOVE.............................8L-22
BOX LAMP SWITCH - REMOVAL, GLOVE . . 8L-22
BOX LATCH - INSTALLATION, GLOVE.....23-64
BOX LATCH - REMOVAL, GLOVE.........23-64
BOX LATCH STRIKER - INSTALLATION,
GLOVE.............................23-64
BOX LATCH STRIKER - REMOVAL,
GLOVE.............................23-64
B-PILLAR - INSTALLATION, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR - REMOVAL, A-PILLAR-
HEADER, OR........................23-17
B-PILLAR LOWER TRIM - INSTALLATION . . 23-75
B-PILLAR LOWER TRIM - REMOVAL.....23-74
B-PILLAR SWITCH - DESCRIPTION, LEFT . 8N-32
B-PILLAR SWITCH - DESCRIPTION,
RIGHT.............................8N-32
B-PILLAR SWITCH - INSTALLATION,
LEFT..............................8N-32
B-PILLAR SWITCH - INSTALLATION,
RIGHT.............................8N-32
B-PILLAR SWITCH - OPERATION, LEFT . . . 8N-32
B-PILLAR SWITCH - OPERATION, RIGHT . . 8N-32
B-PILLAR SWITCH - REMOVAL, LEFT....8N-32
B-PILLAR SWITCH - REMOVAL, RIGHT . . . 8N-32
B-PILLAR UPPER TRIM - INSTALLATION . . 23-75
B-PILLAR UPPER TRIM - REMOVAL......23-75
BRACKET - 2.4L ENGINE -
INSTALLATION, A/C COMPRESSOR
MOUNTING.........................24-76
BRACKET - 2.4L ENGINE - REMOVAL,
A/C COMPRESSOR MOUNTING..........24-75
BRACKET - DESCRIPTION, TRANSVERSE . . 8N-18
BRACKET - INSTALLATION, TRANSVERSE . 8N-18
BRACKET - OPERATION, TRANSVERSE . . . 8N-18
BRACKET - REMOVAL, TRANSVERSE.....8N-18
BRACKET ASSEMBLY - INSTALLATION,
FLOOR CONSOLE TRAY................23-83
BRACKET ASSEMBLY - REMOVAL,
FLOOR CONSOLE TRAY................23-83
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK...........................8E-5
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK...........................8E-6
BRAKE - INSTALLATION, LEVER -
PARKING.......................5-65,5s-67
BRAKE - INSTALLATION, SHOES -
PARKING.......................5-72,5s-75
BRAKE - INSTALLATION, SUPPORT
PLATE - DRUM..................5-56,5s-58
BRAKE - OPERATION, CONTROLLER
ANTILOCK...........................8E-5
BRAKE - REMOVAL, CONTROLLER
ANTILOCK...........................8E-6
BRAKE - REMOVAL, LEVER - PARKING....5-64,
5s-67
BRAKE - REMOVAL, SHOES - PARKING . . . 5-67,
5s-69
BRAKE - REMOVAL, SUPPORT PLATE -
DRUM
.........................5-56,5s-58
BRAKE AUTOMATIC ADJUSTER -
DIAGNOSIS AND TESTING, DRUM
. . . 5-13,5s-13
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE - STANDARD PROCEDURE,
PARKING
.......................5-58,5s-61
BRAKE AUTOMATIC ADJUSTER TENSION
RESET - STANDARD PROCEDURE,
PARKING
.......................5-59,5s-61
BRAKE BLEEDING - STANDARD
PROCEDURE, BASE
.................5-7,5s-7
BRAKE BOOSTER - DESCRIPTION,
POWER
........................5-40,5s-43
BRAKE BOOSTER - DIAGNOSIS AND
TESTING, POWER
................5-41,5s-44
BRAKE BOOSTER - OPERATION, POWER
. . 5-41,
5s-44
BRAKE CABLE (FRONT) - INSTALLATION,
PARKING
.......................5-63,5s-65
BRAKE CABLE (FRONT) - REMOVAL,
PARKING
.......................5-59,5s-62
BRAKE CABLE (INTERMEDIATE) -
INSTALLATION, PARKING
..........5-63,5s-66
BRAKE CABLE (INTERMEDIATE) -
REMOVAL, PARKING
..............5-60,5s-62
BRAKE CABLE (LEFT REAR) -
INSTALLATION, PARKING
..........5-64,5s-66
4 INDEXRS
Description Group-Page Description Group-Page Description Group-Page