how to replace the blend door on 1999 chrysler cirrus?

Blend door removal and installation:------------

On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel from the vehicle.
3. Remove the three screws that secure the blend door actuator to the bottom of the HVAC housing.
   
   NOTE

   When removing the actuator, note the position of the actuator shaft and its respective linkage for installation reference.
   
   
   
   
   

   

   Fig. Blend actuator (1), mode actuator(2) and harness (3)
4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector from the actuator.

To install:

1. Install the blend door actuator onto the bottom of the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door cam.
   
   
   

   

   Fig. Actuator (1), cam spline (2) and actuator spline (3)
2. Install the three screws that secure the blend door actuator to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
3. Connect the HVAC wire harness connector to the blend door actuator.
4. Install the instrument panel.
5. Reconnect the negative battery cable.

Door actuator removal and installation:-------------

On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel from the vehicle.
3. Disconnect the HVAC wire harness connector from the recirculation door actuator.
   
   
   

   

   Fig. Recirculation housing (1) and actuator (2)
4. Remove the three screws that secure the recirculation door actuator to the HVAC air inlet housing.
   
   NOTE

   When removing the actuator, note the position of the actuator shaft and its respective linkage for installation reference.
5. Remove the recirculation door actuator from the HVAC air inlet housing.

To install:

1. Install the recirculation door actuator onto the HVAC air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the actuator gear.
   
   
   

   

   Fig. Door gear (1), actuator gear (2) and recirculation housing (3)
2. Install the three screws that secure the recirculation door actuator to the HVAC air inlet housing. Tighten the screws to 18 inch lbs. (2 Nm).
3. Connect the wire harness connector to the recirculation door actuator.
4. Install the instrument panel.
5. Reconnect the negative battery cable.

RECIRCULATION DOOR CABLE REMOVAL AND INSTALLATION:---------

The cables must be adjusted for proper function of the control module. To adjust the cable, attach the cable to the lever arm of the control module. Turn the knob fully counterclockwise. Pull the cable jacket away from the cable end until taut. Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted.

The RECIRC door is actuated by a cable which mechanically positions the door.

The RECIRC door actuator is located at the far right of the A/C Heater housing near the right A-pillar.

Fig. Temperature door cable (1), control module (2), A/C housing (3) and recirculation door cable (4)

1. Place the ignition key in the OFF position before removing control module.
2. Remove the trim bezel.
   
   
   

   

   Fig. Typical trim bezel
3. Remove the cluster hood bezel retaining screws in the trim bezel opening.
4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws.
5. Remove the cubby bin/cigar lighter bezel and wiring.
6. Remove the control module retaining screws.
7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening then disconnect the wiring on the rear of the control module.
8. Release the recirculation cable retaining clip from the top of the control module. Retain the clip for future use. Then disconnect the recirculation control cable.
9. Remove the right under panel silencer/duct.
10. Disconnect cable flag at right of recirculation housing.
    
    
    

    

    Fig. Disconnecting recirculation door cable (1)
11. Remove the cable core end from recirculation actuator lever.

To install:

Install the in reverse order of removal. Verify that the cables are properly adjusted, free of interference and the module is seated properly.

TEMPERATURE DOOR CABLE

The blend-air (temperature) door is actuated by a cable which mechanically positions the temperature door.

The temperature door actuator is located at the center of the A/C Heater housing at the center tunnel.

Fig. Temperature door cable (1), control module (2), A/C housing (3) and recirculation door cable (4)

1. Place the ignition key in the OFF position before removing control module.
2. Remove the trim bezel
   
   
   

   

   Fig. Typical trim bezel
3. Remove the cluster hood bezel retaining screws in the trim bezel opening.
4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws.
5. Remove the cubby bin/cigar lighter bezel and wiring.
6. Remove the control module retaining screws.
7. Remove the control module and disconnect the wire connectors.
8. Release the temperature control cable retaining clip from the top of the control module. Retain the clip for future use. Then disconnect the temperature control cable.
9. Disconnect cable at A/C housing.
   
   
   

   

   Fig. Temperature cable at A/C housing
10. Remove the cable core end from temperature actuator lever.

To install:

Installation is the reverse of removal.

------------

The main control panel removal and installation:-----------

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
3. Remove or disconnect the following:
   
   NOTE

   When the control panel assembly is out, it will have to be disconnected from the wire harness and control cables.
   
   
   
   
   Center panel assembly

   Front driver's side under cover

   Front passenger's side under cover

   Radio/tape/CD player

   Floor console

   Instrument panel center reinforcement

   Foot duct (LH)

   Control panel assembly
   
   
   
   
   Light bulb harness

   Defroster switch

   Air mix damper control cable

   Air outlet changeover control cable

To install:

1. Attach control cables to control panel
   1. Set the air outlet changeover control knob on the heater control assembly to the defroster position.
   2. Set the air outlet changeover damper link of the heater/cooler unit to the defroster position as shown in the illustration, and then connect the cable to the link pin.
   3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip.
2. Install or connect the following:
   
   
   Defroster switch

   Light bulb harness

   Control panel assembly

   Foot duct (LH)

   Instrument panel center reinforcement

   Floor console

   Radio/tape/CD player

   Front passenger's side under cover

   Front driver's side under cover

   Center panel assembly

The control module is located below the radio

1. Place the ignition key in the OFF position before removing control module.
2. Remove the trim bezel.
   
   
   

   

   Fig. Removing bezel trim
3. Remove the cluster hood bezel retaining screws in the trim bezel opening.
   
   
   

   

   Fig. Control module screws (1) and cluster hood screws (2)
4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws.
5. Remove the cubby bin/cigar lighter bezel and wiring.
6. Remove the control module retaining screws.
7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening then disconnect the wiring on the rear of the control module.
8. Release the cable clips from the top of the control module. Retain the clips for future use.
9. Disconnect the temperature control and recirculation control cables.
10. Remove the control module.

To install:

Installation is the reverse of removal. Make sure the cables are properly adjusted and the module is seated properly.

The cables must be adjusted for proper function of the control module. To adjust the cables:

1. Attach the cable to the lever arm of the control module.
2. Turn the knob fully counterclockwise.
3. Pull the cable jacket away from the cable end until taut.
4. Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted.

CAUTION

On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death.

1. Disconnect and isolate the battery negative cable.
2. Remove the center bezel from the instrument panel.
3. Place the center bezel on a workbench and remove the six screws that secure the A/C-heater control to the center bezel.
4. Remove the A/C-heater control from the center bezel.
5. Connect the negative battery cable.
   
   
   

   

   Fig. A/C heater control - typical

To install:

1. Position the A/C-heater control into the instrument panel center bezel.
2. Install the six screws that secure the A/C-heater control to the center bezel. Tighten the screws to 18 inch lbs. (2 Nm).
3. Install the instrument panel center bezel.
4. Reconnect the battery negative cable.

---------------

Heater core removal and installation:-----------

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable. Properly drain the cooling system.
3. Disconnect the heater hoses from the heater core.
4. Remove the floor console by removing or disconnecting the following:
   
   
   Center console panel

   Shift knob

   Accessory box or ashtray

   Floor console panel assembly

   Shift lever cover assembly

   Floor console assembly
5. From under the steering wheel, remove the hood lock release handle, the driver-s side under cover and the lap cooler grille.
6. Remove the steering wheel by removing or disconnecting the following:
   
   
   Air bag module-to-steering wheel screws (rear of the steering wheel) and the air bag module

   Steering wheel-to-column nut and press the steering wheel from the column

   Lower steering column cover screws, the lower cover, the upper cover and the column pad
7. Remove the instrument panel by removing or disconnecting the following:
   
   
   Meter bezel and the combination meter

   Radio and tape player

   Console side cover

   Sunglass holder

   Glove box stopper and the glove box

   Passenger-s side air bag module

   Passenger-s side air bag module electrical connector

   Center air outlet assembly

   Instrument panel switch

   Instrument panel switch electrical connectors

   Right side instrument panel under cover

   Front speaker

   Instrument panel
8. Remove the attaching clip and nuts and remove the heater unit.
9. Remove the heater core from the heater unit.
   
   CAUTION

   Do not let the heater core bump against the SRS-ECU or its components.
   
   
   
   
   

   

   Fig. Exploded view of the center console
   
   
   
   

   

   Fig. Exploded view of the ventilators and related components
   
   
   
   

   

   Fig. Exploded view of the steering column and related components
   
   
   
   

   

   Fig. Exploded view of the instrument panel and related components
   
   
   
   

   

   Fig. Exploded view of the heater core housing and related components
   
   
   
   

   

   Fig. Exploded view of the evaporator core housing and related components
   
   
   
   

   

   Fig. Exploded view of the manual control head and related components

To install:

1. Install or connect the following components:
   
   
   Heater core into the heater unit

   Heater unit and attach the nuts and clip

   Instrument panel by reversing the removal procedures

   Steering column pad, the upper cover, the lower cover and the lower steering column cover screws

   Steering wheel by reversing the removal procedure

   Lap cooler grille, the driver-s side under cover and the hood lock release handle

   Floor console by reversing the removal procedure

   Heater hoses to the heater core
2. Refill the cooling system.
3. Connect the negative battery cable. Check for leaks.

1. Disconnect the negative battery cable.
2. Drain the cooling system into a clean container for reuse.
3. From the center of the instrument panel, grasp and pull to remove the radio/control module bezel.
   
   
   

   

   Fig. Exploded view of the instrument panel assembly
   
   
   
   

   

   Fig. Junction block location-Cirrus, Stratus, Sebring convertible and Breeze
4. At the right side of the instrument panel, remove the side trim.
   
   
   

   

   Fig. Unlock the glove box door stoppers by pushing in the direction shown-Cirrus, Stratus, Sebring Convertible and Breeze
5. Remove or disconnect the following:
   
   
   2 lower right side support beam screws

   Instrument panel support-to-A-pillar bolt

   On left side of the instrument panel, remove the side trim

   Upper instrument panel bezel

   Lower knee bolster

   Console-to-instrument panel screws

   Gearshift knob and the shifter bezel

   Rear console screws and the rear console half

   Front console screws and the front console half

   Right side instrument panel support strut

   Heater hoses from the heater core tubes

   Heater core cover-to-heater/air conditioning housing assembly screws and the cover

   Heater core from the heater/air conditioning housing assembly
   
   

   

   

   Fig. View of the heater/air conditioning housing assembly-Cirrus, Stratus and Breeze

   
   
   

   

   

   Fig. View of the heater housing assembly and the heater core-Cirrus, Stratus and Breeze

To install:

1. Install or connect the following:
   
   
   Heater core to the heater/air conditioning housing assembly

   Heater core cover and the cover-to-heater/air conditioning housing assembly screws

   Heater hoses to the heater core tubes

   Right side instrument panel support strut

   Front console half and the front console screws

   Rear console half and the rear console screws

   Shifter bezel and the gearshift knob

   Console-to-instrument panel screws

   Lower knee bolster

   Upper instrument panel bezel

   On left side of the instrument panel, install the side trim

   Instrument panel support-to-A-pillar bolt

   2 lower right side support beam screws

   Right side of the instrument panel, install the side trim

   On center of the instrument panel, install the radio/control module bezel
2. Refill the cooling system.
3. Connect the negative battery cable.
4. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

CAUTION

On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

NOTE

The instrument panel and HVAC housing are removed from the vehicle together as an assembly.

1. Recover the refrigerant from the refrigerant system.
2. Drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Remove the one bolt retaining the A/C lines to the right strut tower.
5. Remove the two top HVAC housing retaining nuts in engine compartment.
6. Hoist vehicle and remove the lower HVAC housing retaining nut.
7. Lower vehicle from hoist.
8. Remove the driver-s and passenger-s seats:
   1. Position seat far enough forward to gain access to rear mount bolts on floor.
   2. Remove bolts holding rear of seat track to floor.
   3. Slide seat rearward.
   4. Remove bolts attaching front of the seat track to floor kick up.
   5. Disconnect negative battery cable, if electrical seat.
   6. Disconnect front seat wire harness connector from body harness connector.
      
      CAUTION

      Do not handle seat by adjuster release bar when removing spring loaded seat from vehicle.
   7. Remove front seat from vehicle.
9. Disconnect and isolate the battery negative remote cable.
10. Remove the one screw to shift knob and transmission range indicator bezel from floor console.
11. Remove the floor center console. Remove two mounting screws in the front and two mounting screws inside console storage bin.
12. Remove the amplifier retaining fasteners.
13. Disconnect the wire harness connector.
14. Remove the amplifier.
15. Using a trim stick or equivalent, gently pry out on the left and right rear floor heat ducts and remove.
16. Disconnect the console wiring connectors and unclip the push in fasteners.
17. Using a trim stick or equivalent, gently pry up on and remove the right sill plate.
18. Remove the two screws to the right cowl kick panel and remove from vehicle.
19. Using a trim stick or equivalent, gently pry out on the right end cover and remove from vehicle.
20. Using a trim stick or equivalent, gently pry out on the right A-pillar trim and remove from vehicle.
21. Open the glove box. Pinch in on the sides and drop to the floor. Pull down to disengage hinges.
22. Disconnect the right door harness connectors located within the A-pillar.
23. Remove the four right A-pillar instrument panel retainers.
24. Remove the right silencer.
25. Remove the one right side, center instrument panel support bolt.
26. Using a trim stick or equivalent, gently pry up on and remove the left sill plate.
27. Remove the two screws to the left cowl kick panel and remove from vehicle.
28. Using a trim stick or equivalent, gently pry out on the left end cover and remove from vehicle.
29. Using a trim stick or equivalent, gently pry out on the left A-pillar trim and remove from vehicle.
30. Disconnect the left door harness connectors located within the A-pillar.
31. Remove the four left A-pillar instrument panel retainers.
32. Remove the five screws and one wire connector to left lower instrument panel trim bezel.
33. Remove the left silencer.
34. Remove the one left side, center instrument panel support bolt.
35. Remove the one bolt to the left side support strut to bulkhead.
36. Disconnect the junction block wiring connectors.
37. Remove the two screws to the steering column shrouds and remove.
38. Disconnect all the column wiring and unclip the harness from the steering column.
39. Disconnect the transmission shift interlock and wire connector.
40. Remove the four steering column retaining bolts and drop column to floor.
41. Using a trim stick or equivalent, pry up on the rear of the top cover and pull rearward as you lift it off of instrument panel.
42. Remove the instrument panel pad.
43. Remove the seven bolts and five screws attaching instrument panel to fence line and cowl side.
44. With the help of an assistant, lift up instrument panel and move rearward to remove. Tilt the panel rearward to prevent the coolant from leaking out. If replacing the instrument panel, transfer all non-damaged parts and wiring harness to the new instrument panel assembly.
45. Disconnect HVAC wire harness from the instrument panel wire harness connector at the left side of the HVAC housing.
46. Remove the two nuts and two bolts that secure the HVAC housing to the instrument panel.
47. Separate the HVAC housing from the instrument panel.
48. Disconnect the HVAC wire harness connectors from the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
49. Remove the two screws that secure the HVAC harness connector to the HVAC housing and remove the HVAC wire harness.
50. Remove the screws that secure the blower motor to the HVAC housing and remove the blower motor.
51. Remove the screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove it from the housing.
52. Remove the screws that secure the air inlet housing to the HVAC housing and remove the air inlet housing.
53. Remove the three screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.
54. Remove the screw that secures the recirculation door actuator gear to the air inlet housing and remove the gear.
55. Using a small screwdriver, depress the recirculation door gear release and remove the recirculation door gear from the recirculation door shaft.
    
    NOTE

    If the seals on the recirculation-air door is deformed or damaged, the air door must be replaced.
56. Tilt the gear end of the recirculation-air door up and pull the door out of the air inlet housing.
    
    NOTE

    If either foam seal is deformed or damaged, it must be replaced.
57. Carefully, remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing.
58. Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves.
59. Using a flat blade pry tool, disengage the locking tab on the access plate of the evaporator temperature sensor. Turn the access plate clockwise one quarter turn and push the access plate inside of the HVAC housing, then orientate the plate in such a way that it can be removed from the housing.
60. Remove the evaporator temperature sensor probe from the A/C evaporator and remove the sensor.
61. Lift the A/C evaporator out of the bottom half of the HVAC housing.
62. Lift the heater core out of the bottom half of the HVAC housing.
    
    
    

    

    Fig. HVAC housing
    
    
    
    

    

    Fig. Heater core

To install:

1. Install the heater core into the bottom half of the HVAC housing.
2. Align the blend and mode door shafts with the holes in the HVAC housing and install the top half of the housing to the bottom half of the housing.
3. Install the screws that secure the two halves of the HVAC housing together. Tighten the screws to 18 inch lbs. (2 Nm).
4. Install the foam seals on the heater core and evaporator coil tube mounting flange.
5. Install the recirculation-air door into the air inlet housing.
6. Install the recirculation door gear onto the recirculation door shaft.
   
   NOTE

   The recirculation door actuator gear and door gear must be properly aligned to operate correctly.
7. Align and install the recirculation door actuator gear with the door gear.
8. Install the screw that secure the recirculation door actuator gear to the air inlet housing. Tighten the screw to 18 inch lbs. (2 Nm).
9. Align the recirculation door actuator spline with the spline in the recirculation door gear and install the recirculation door actuator.
10. Install the three screws that secure the recirculation door actuator to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
11. Install the air inlet housing onto the HVAC housing.
12. Install the screws that secure the air inlet housing to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
13. If removed, install the blower motor resistor or power module (depending on application). Install and tighten the screws to 18 inch lbs. (2 Nm).
14. If removed, install the blower motor. Install and tighten the screws to 18 inch lbs. (2 Nm).
    
    NOTE

    Make sure that all HVAC wire harness leads are routed through all HVAC housing wiring retainers.
15. Install the HVAC wire harness onto the HVAC housing.
16. Install the two screws that secure the HVAC wire harness connector to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
17. Connect the HVAC wire harness connectors to the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
18. Position the HVAC housing to the instrument panel. Make sure that all air ducts are properly aligned or connected.
19. Install the two nuts and bolts that secure the HVAC housing to the instrument panel. Tighten the nuts and bolts securely.
20. Connect the HVAC wire harness to the instrument panel wire harness connector.
    
    NOTE

    Verify that the evaporator drain tube and evaporator seals are properly seated to the HVAC housing before installing the instrument panel and HVAC Housing into the vehicle.
21. With the help of an assistant, place the instrument panel in the vehicle, carefully guiding the HVAC housing studs through the bulkhead and into position.
22. Install the seven bolts and five screws attaching instrument panel to fence line and cowl side.
23. Place instrument panel pad into position.
24. Place instrument panel top cover in position on vehicle.
25. Push top cover forward to engage hooks to hold front of top cover to instrument panel.
26. Engage clips to hold rear edge of top cover to instrument panel.
27. Pull top cover rearward as you firmly push down and snap into place.
28. Install the A-pillar trim.
29. Install the four steering column retaining bolts.
30. Connect the transmission shift interlock and wire connector.
31. Connect all the column wiring and clip the harness to the steering column.
32. Install the two screws to the steering column shrouds.
33. Connect the junction block wiring connectors.
34. Install the one bolt to the left side support strut to bulkhead.
35. Install the five screws and one wire connector to left lower instrument panel trim bezel.
36. Install the one left side, center instrument panel support bolt.
37. Install the left silencer.
38. Install the four left A-pillar instrument panel retainers.
39. Connect the right door harness connectors located within the A-pillar.
40. Install the left end cover.
41. Install the two screws to the left cowl trim panel.
42. Install the left door sill plate.
43. Install the one right side, center instrument panel support bolt.
44. Install the right silencer.
45. Install the four right A-pillar instrument panel retainers.
46. Connect the right door harness connectors located within the A-pillar.
47. Install the glove box.
48. Install the right A-pillar trim.
49. Install the right end cover.
50. Install the two screws to the right cowl trim panel.
51. Install the right door sill plate.
52. Connect the console wiring connectors and clip the push in fasteners in.
53. Install the left and right rear floor heat ducts.
54. Connect the two harness connectors to the amplifier.
55. Connect wire harness connector to amplifier.
56. Install the amplifier. Tighten the forward screw to 26.5 inch lbs. (3 Nm) and the rear nut to 18 inch lbs. (2 Nm).
57. Install the floor center console. Install the two mounting screws in the front and two mounting screws inside console storage bin.
58. Install the transmission range indicator bezel and one screw to shift knob.
59. Connect the battery negative remote cable.
    
    CAUTION

    Do not handle by seat adjuster release bar.
    
    
    
    NOTE

    Ensure that the seat tracks are rearward. Ensure the seat tracks on the right and left are in equal latch positions.
60. Place front seat in position in vehicle.
61. Connect front seat wire harness connector to body harness connector.
62. Install the bolts to attach front of seat track to the floor kick up. Tighten bolts to: 45 ft. lbs. (61 Nm).
63. Slide seat forward and install the bolts attaching rear of seat track to the floor. Tighten bolts to 45 ft. lbs. (61 Nm).
64. Verify front seat operation.
65. Hoist vehicle and install the lower HVAC housing retaining nut.
66. Lower vehicle from hoist.
67. Install the two top HVAC housing retaining nuts in engine compartment.
68. Install the one bolt retaining the A/C lines to the right strut tower.
69. Reconnect the negative battery cable.
70. If the heater core is being replaced, flush the cooling system.
71. Refill the engine cooling system.
72. Evacuate the refrigerant system.
73. Charge the refrigerant system.

---------------

Blower motor removal and installation:------------

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
3. Remove or disconnect the following:
   
   
   Glove box assembly

   Joint duct

   Resistor

   Blower fan and motor

   Air changeover damper motor

   Blower assembly

To install:

1. Install or connect the following:
   
   NOTE

   Lubricate the damper motor's slide contacts with multi-purpose grease
   
   
   
   
   Blower assembly into duct

   Air changeover damper motor and reconnect the electrical plug
   
   
   
   
   Blower fan and motor into the plenum and reconnect the electrical plug

   Resistor on the joint duct

   Joint duct to blower assembly

   Glove box assembly

The blower motor is located on the right side of the heater housing.

1. Disconnect battery.
2. Remove the lower right under panel silencer duct.
3. Remove the blower motor connector from resistor block.
4. Remove the blower motor case retaining screws.
5. Lower blower motor case from housing
6. Remove the fan scroll from motor shaft.
7. Remove the motor from motor case.
   
   
   

   

   Fig. Blower motor (1)

To install:

1. Install the in reverse order of removal.

CAUTION

On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel silencer from the passenger side of the instrument panel.
   1. Remove two push-in fasteners under right end of instrument panel.
   2. Maneuver part off center floor distribution duct to remove.
3. Disconnect the wire harness connector from the blower motor.
4. Remove the three screws that secure the blower motor to the HVAC housing.
5. Remove the blower motor from the HVAC housing by rotating and tilting the motor as needed for clearance of the blower wheel.
   
   
   

   

   Fig. Blower wheel (1) and blower motor (2)

To install:

1. Position the blower motor into the HVAC housing.
2. Install the three screws that secure the blower motor to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
3. Connect the wire harness connector to the blower motor.
4. Install the instrument panel silencer onto the passenger side of the instrument panel.
5. Reconnect the negative battery cable.

-----------------

Compressor removal and installation:-------

CAUTION

Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

Refer to the precautions at the beginning of this section.

Use a refrigerant recovery unit to discharge refrigerant gas from the system.

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
3. Remove or disconnect the following:
   
   
   Condenser fan motor (3.0L engine)

   Drive belt

   High and low pressure hoses from A/C compressor and discard the O-rings

   A/C compressor from bracket

To install:

1. Install or connect the following:
   
   WARNING

   Be certain to lubricate the O-rings with PAG A/C compressor oil
   
   
   
   
   A/C compressor to bracket

   High and low pressure hoses to A/C compressor with new O-rings
   
   
   
   
   Drive belt and tension to 90-110 lbs. (400-490 N) for a used belt or 110-160 lbs. (490-712 N) for a new belt.

   Condenser fan motor (3.0L engine)

1. Disconnect the battery negative cable.
2. Loosen and remove accessory drive belt (refer to Engine Mechanical Section of this Manual).
3. Disconnect compressor clutch harness connector.
4. Recover refrigerant system with R-134a recovery unit (refer to Evacuating the System procedure in this section).
5. Remove the refrigerant lines from compressor .
   
   
   

   

   Fig. A/C compressor suction port (1) and discharge port (2)
6. Remove the compressor attaching bolts.
7. Remove the compressor.

To install:

1. Position the compressor on the mount.
2. Install the compressor attaching bolts. Tighten bolts to 30 ft. lbs. (41 Nm).
3. Install the drive belt (refer to Engine Mechanical Section of this Manual).
4. Install the refrigerant hoses and new seals.
5. Connect the clutch harness connector.
6. Charge the system (refer to the Charging the System procedure in this section).
7. Connect the negative cable to the battery.

1. Recover the refrigerant from the refrigerant system (refer to Evacuating the System procedure in this section).
2. Disconnect and isolate the negative battery cable.
3. Remove the accessory drive belt (refer to Engine Mechanical Section of this Manual).
4. Disconnect the harness connector from the A/C compressor clutch coil connector.
5. Remove the bolts that secure the A/C suction line and A/C discharge line to the A/C compressor.
   
   
   

   

   Fig. Typical A/C compressor with discharge line (1), suction line (2), compressor (3) and mounting bolt (4)
6. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals.
7. Install the plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
8. Raise and support vehicle.
9. Remove the bolts that secure the A/C compressor to the mounting bracket.
10. Remove the A/C compressor from the engine compartment.

To install:

NOTE

Be certain to check the refrigerant oil level if the A/C compressor is being replaced. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. Position the A/C compressor onto the mounting bracket.
2. Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 20 ft. lbs. (28 Nm).
3. Lower the vehicle.
4. Remove the tape or plugs from the opened fittings on the A/C suction line and the A/C discharge line and the compressor ports.
5. Lubricate the new O-ring seals with clean refrigerant oil and install the them onto the suction and the discharge line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
6. Install the A/C suction and discharge lines onto the A/C compressor.
7. Install the bolts that secure the A/C suction and discharge lines to the A/C compressor. Tighten the bolts to 16 ft. lbs. (22 Nm).
8. Connect the wire harness connector to the A/C compressor clutch coil connector.
9. Install the accessory drive belt (refer to Engine Mechanical Section of this Manual).
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system (refer to Evacuating the System procedure in this section).
12. Charge the refrigerant system (refer to Charging the System procedure in this section).

CAUTION

Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.