2005 CHRYSLER CARAVAN steering wheel

BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors. Models with the
single zone heater and air conditioner system have a
single blend air door, which is controlled by a single
blend door actuator. Models with the optional dual
zone front heater and air conditioner system have
dual blend air doors, which are controlled by two
blend door actuators. The single zone blend door
actuator is located on the driver's side end of the
HVAC housing, close to the middle of the distribution
housing. In the dual zone system, the same blend
door actuator used for the single zone system
becomes the passenger blend door actuator, and is
mechanically connected to only the passenger side
blend air door. In the dual zone system, a second sep-
arate blend door actuator is also located on the
driver side end of the HVAC housing, close to the
middle of the distribution housing, and is mechani-
cally connected to only the driver's side blend air
door.
The blend door actuators are interchangeable with
each other, as well as with the actuators for the
mode door and the recirculation air door. Each actua-
tor is contained 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 distri-
bution housing. Each actuator also has an identical
output shaft with splines that connects it to the link-
age that drives the proper blend air door. The blend
door actuators do not require mechanical indexing to
the blend door linkage, as they are electronically cal-
ibrated by the heater-A/C control module.
OPERATION
The blend door actuators are connected to the A/C-
heater control through the vehicle electrical system
by a dedicated two-wire lead and connector of the
HVAC wire harness. The blend door actuator(s) can
move the blend-air door(s) in two directions. When
the A/C-heater control pulls the voltage on one side
of the motor connection high and the other connec-
tion low, the blend-air door will move in one direc-
tion. When the A/C-heater control reverses the
polarity of the voltage to the motor, the blend-air
door moves in the opposite direction.
When the A/C-heater control makes the voltage to
both connections high or both connections low, the
blend-air door stops and will not move. The A/C-
heater control uses a feedback signal positioning sys-
tem to monitor the operation and relative position of
the blend door actuator(s) and the blend-air door(s).
The A/C-heater control learns the blend-air door stoppositions during the calibration procedure and will
store a diagnostic trouble code (DTC) for any prob-
lems it detects in the blend door actuator circuits.
The blend door actuators are diagnosed using a
scan tool (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING and to 24 -
HVAC Electrical Diagnostics for more information).
The blend door actuators cannot be adjusted or
repaired and, if faulty or damaged, they must be
replaced.
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.
NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. The dual zone system has two blend door
actuators, one for the driver side blend air door and
one for the passenger side blend air door. The
same service procedures can be used for each of
these actuators.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the wire harness connector from the
blend door actuator(s) (Fig. 11).
(4) Remove the two screws that secure the blend
door actuator to the distribution housing.
(5) Remove the blend door actuator.
INSTALLATION
(1) Position the blend door actuator onto the distri-
bution housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the blend air door linkage.
(2) Install the two screws that secure the blend
door actuator to the housing. Tighten the screws to 2
N´m (17 in. lbs.).
24 - 22 CONTROLS - FRONTRS

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
FRONT 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 motorrelay 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.
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.
RSCONTROLS - FRONT24-25
BLOWER MOTOR RESISTOR BLOCK (Continued)

MODE DOOR ACTUATOR
DESCRIPTION
The mode door actuator is a reversible, 12-volt
Direct Current (DC), servo motor. The single mode
door actuator is located on the driver's side end of
the HVAC housing, close to the top of the distribution
housing. The mode door actuator is mechanically con-
nected to the mode door.
The mode door actuator is interchangeable with
the actuators for the blend air door(s) and the recir-
culation air door. Each actuator is contained 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 distribution housing. Each actuator
also has an identical output shaft with splines that
connects it to the linkage that drives the mode door.
The mode door actuator does not require mechanical
indexing to the mode door linkage, as it is electroni-
cally calibrated by the heater-A/C control module.
OPERATION
The mode door actuator is connected to the A/C-
heater control through the vehicle electrical system
by a dedicated two-wire lead and connector from the
HVAC wire harness. The mode door actuator can
move the mode door in two directions. When the A/C-
heater control pulls the voltage on one side of the
motor connection high and the other connection low,
the mode door will move in one direction. When the
A/C-heater control reverses the polarity of the volt-
age to the motor, the mode door moves in the oppo-
site direction. When the A/C-heater control makes
the voltage to both connections high or both connec-
tions low, the mode door stops and will not move.
These same motor connections also provide a feed-
back signal to the A/C-heater control. This feedback
signal allows the A/C-heater control to monitor the
operation and relative position of the mode door
actuator and the mode door. The A/C-heater control
learns the mode door stop positions during the cali-
bration procedure and will store a diagnostic trouble
code (DTC) for any problems it detects in the mode
door actuator circuits.
The mode door actuator can be diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures for more information. The mode door actuator
cannot be adjusted or repaired and, if damaged or
faulty, it must be replaced.
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 silencer from beneath the driver
side end of the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the wire harness connector from the
mode door actuator (Fig. 20).
(4) Remove the two screws that secure the mode
door actuator to the HVAC distribution housing.
(5) Remove the mode door actuator from the distri-
bution housing.
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 - FRONT24-29

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. 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 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.
WARNING: THE HEAT SINK FOR THE BLOWER
MOTOR POWER MODULE MAY GET VERY HOT
DURING NORMAL OPERATION. IF THE BLOWER
MOTOR WAS TURNED ON PRIOR TO SERVICING
THE BLOWER MOTOR POWER MODULE, WAIT
FIVE MINUTES TO ALLOW THE HEAT SINK TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
24 - 30 CONTROLS - FRONTRS
MODE DOOR ACTUATOR (Continued)

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
24 - 32 CONTROLS - FRONTRS
RECIRCULATION DOOR ACTUATOR (Continued)

REMOVAL
FRONT 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)
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.
FRONT DEMISTER OUTLETS
(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.
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
24 - 44 DISTRIBUTION - FRONTRS
AIR OUTLETS (Continued)

whenever the ignition switch is in the On position
and the A/C-heater control power is turned on.
The blower motor receives battery current when-
ever the front blower motor relay is energized. The
front blower motor relay output circuit is protected
by a fuse in the Integrated Power Module (IPM)
located in the engine compartment near the battery.
In the manual heater-A/C system, the blower motor
speed is controlled by regulating the path to ground
through the blower control switch and the blower
motor resistor. In the ATC system, the blower motor
speed is controlled by an electronic blower motor
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
blower motor to regulate the blower motor ground
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
FRONT 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) or
the 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).
24 - 46 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)

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 OR DEATH.
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 negative battery
cable.
(2) Remove the passenger side cowl trim panel
(Refer to 23 - BODY/INTERIOR/COWL TRIM -
REMOVAL).
(3) Pull back the carpet to access the front upper
screw that secures the air inlet housing.
(4) Remove the recirculation door actuator (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/RECIRCULATION DOOR ACTUA-
TOR - REMOVAL).
(5) Remove the recirculation door actuator wire
lead from the routing clip located on the lower air
inlet housing and position the wire lead aside.
(6) Disconnect the blower motor wire lead connec-
tor from the blower motor resistor block or power
module, depending on application.
(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 upper air
inlet housing and the lower HVAC housing.
(9) Push the rubber blower motor wire lead grom-
met through the opening in the lower air inlet hous-
ing (Fig. 9).
(10) Feed the blower motor wire lead through the
opening in the lower air inlet housing and remove
the lower air inlet housing from the vehicle.(11) Position 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.
Fig. 8 Lower Air Inlet Housing
1 - BLOWER MOTOR RESISTOR BLOCK/POWER MODULE
2 - BLOWER MOTOR WIRE LEAD
3 - LOWER HVAC HOUSING
4 - UPPER AIR INLET HOUSING
5 - UPPER SCREW (1)
6 - LOWER AIR INLET HOUSING
7 - RECIRCULATION DOOR ACTUATOR
8 - ACTUATOR WIRE LEAD
9 - LOWER SCREW (4)
Fig. 9 Blower Motor Wire Lead Grommet
1 - BLOWER MOTOR WIRE LEAD GROMMET
24 - 48 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)