Chrysler RG Voyager. Manual - part 1221

INSTALLATION

(1) Position the blower motor and wheel to the

lower half of the HVAC housing. Align the blower
motor mounting tabs to the correct location on the
HVAC housing.

(2) Gently flex the recirculation-air door far down

enough to install the blower motor and wheel into
the HVAC housing.

(3) Position the recirculation-air door as necessary

to install the three screws that secure the blower
motor to the HVAC housing. Tighten the screws to 2
N·m (17 in. lbs.).

(4) Feed the blower motor wire lead through the

opening in the lower air inlet housing and seat the
rubber grommet into the lower air inlet housing.

(5) Position the recirculation-air door pivot into

the lower air inlet housing.

(6) Install the four screws (from the bottom) that

secure the lower air inlet housing to the upper air
inlet housing and 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
inlet housing. Tighten the screws to 2 N·m (17 in.
lbs.).

(8) Connect the blower motor wire lead connector

to the blower motor resistor or power module,
depending on application.

(9) Install the recirculation door actuator wire lead

into the routing clip located on the lower air inlet
housing.

(10) Install the recirculation door actuator (Refer

to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/RECIRCULATION DOOR ACTUA-
TOR - INSTALLATION).

(11) Reinstall the carpet.
(12) Install the passenger side cowl trim panel

(Refer to 23 - BODY/INTERIOR/COWL TRIM -
INSTALLATION).

(13) Reconnect the negative battery 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).

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. 10).

(3) Pull the center floor distribution duct rearward

and disengage it from the floor outlet of the front
HVAC housing.

(4) Disassemble the right and/or left floor distribu-

tion ducts from the center floor distribution duct as
required.

INSTALLATION

(1) Install the right and/or left floor distribution

duct onto the center floor distribution duct as
required.

(2) Position the center floor distribution duct

under the instrument panel center stack and engage
it to the floor outlet of the front HVAC housing.

(3) Align the locator hole on the center floor distri-

bution duct with the weld stud on the front floor
panel and install the distribution duct onto the weld
stud.

(4) Install the carpet onto the front floor panel and

under the instrument panel (Refer to 23 - BODY/IN-
TERIOR/CARPETS AND FLOOR MATS - INSTAL-
LATION).

HVAC HOUSING

DESCRIPTION

NOTE: LHD model shown in illustration. RHD model
similar.

Fig. 10 Floor Distribution Ducts - LHD Shown, RHD

Typical

1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD

DISTRIBUTION - FRONT

24 - 49

BLOWER MOTOR (Continued)

All models are equipped with a common HVAC

housing assembly that combines A/C and heating
capabilities into a single unit mounted within the
passenger compartment (Fig. 11). The HVAC housing
assembly consists of three separate housings:

• HVAC housing — The HVAC housing is

mounted to the dash panel behind the instrument
panel and contains the A/C evaporator and the
blower motor resistor or power model (depending on
application)

and

the

particulate

air

filter

(if

equipped). The HVAC housing consists of a upper
and a lower housing that are attached together and
has mounting provisions for the air inlet housing,
blower motor, air distribution housing and the HVAC
wire harness.

• Air inlet housing — The air inlet housing is

mounted to the right end of the HVAC housing and
contains the recirculation-air door and actuator.

• Air distribution housing — The air distribu-

tion housing is mounted to the rear of the HVAC
housing and contains the heater core, blend-air doors
and actuators, mode-air doors and actuator and door
linkage.

The heating-A/C system is a blend-air type system.

The blend-air doors control the amount of condi-
tioned air that is allowed to flow through, or around,
the heater core. The dual zone heating A/C system
uses two blend door actuators.

The A/C system is designed for the use of a non-

CFC, R-134a refrigerant and uses an A/C evaporator
to cool and dehumidify the incoming air prior to
blending it with the heated air. A temperature con-
trol determines the discharge air temperature by

operating the blend door actuators, which moves the
blend-air doors. This allows an almost immediate
control of the output air temperature of the system.
The mode door actuator operates the mode-air doors
which direct the flow of the conditioned air out the
various air outlets, depending on the mode selected.
The recirculation door actuator operates the recircu-
lation-air door which closes off the fresh air intake
and recirculates the air already inside the vehicle.
The electric door actuators are connected to the vehi-
cle electrical system by the HVAC wire harness. The
blower motor controls the velocity of air flowing
through the HVAC housing assembly by spinning the
blower wheel within the HVAC housing at the
selected speed by use of the blower motor resistor or
power model, depending on application.

The air distribution housing must be removed from

the HVAC housing and disassembled for service of
the mode-air and blend-air doors. The air inlet hous-
ing must be removed from HVAC housing and disas-
sembled for service of the recirculation-air door. The
HVAC housing must be removed from the vehicle and
disassembled for service of the A/C evaporator.

REMOVAL

AIR DISTRIBUTION HOUSING

WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing 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 air-
bag system. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.

WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT - WARNINGS)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTIONS). Failure to follow
the warnings and cautions could result in possible
personal injury or death.

NOTE:

The

air

distribution

housing

must

removed from the HVAC housing and disassembled
for service of the mode-air and blend-air doors.

Fig. 11 HVAC Housing Assembly

1 - HVAC HOUSING
2 - AIR INLET HOUSING
3 - AIR DISTRIBUTION HOUSING

24 - 50

DISTRIBUTION - FRONT

HVAC HOUSING (Continued)

NOTE: LHD model shown in illustrations. RHD
model similar.

(1) Remove the HVAC housing from the vehicle

and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).

(2) Disconnect the HVAC wire harness connectors

from the mode door actuator and the blend door
actuator(s) located on the driver side of the air dis-
tribution housing and position the HVAC wire har-
ness out of the way (Fig. 12).

(3) Remove the foam seal from the heater core

tubes and the flange located at the front of the HVAC
housing (Fig. 13). If the seal is deformed or damaged,
it must be replaced.

(4) Remove the plastic retaining strap that secures

the heater core tubes to the front of the HVAC hous-
ing.

NOTE: Take the proper precautions to protect
against spilled engine coolant. Have absorbent tow-
eling readily available to clean up any spills.

(5) Remove the bolt that secures the heater core

tube sealing plate to the heater core.

(6) Disconnect the heater core tubes from the

heater core and remove and discard the O-ring seals.

(7) Install plugs in, or tape over the opened heater

core ports.

(8) Remove the four screws that secure the air dis-

tribution housing to the rear of the HVAC housing
(Fig. 14).

(9) Tilt the top of the air distribution housing rear-

ward to disconnect the distribution housing from the
two tab-and-slot type retainers located at the bottom
of the housing and remove the distribution housing.

(10) If required, disassemble the air distribution

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - FRONT/HVAC HOUS-
ING

AIR

DISTRIBUTION

HOUSING

DISASSEMBLY).

AIR INLET HOUSING

Fig. 12 Actuators

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)

Fig. 13 Heater Core Tubes

1 - FOAM SEAL
2 - RETAINING STRAP
3 - HEATER CORE
4 - SEALING PLATE
5 - SCREW
6 - HVAC HOUSING
7 - HEATER CORE TUBES

DISTRIBUTION - FRONT

24 - 51

HVAC HOUSING (Continued)

WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing 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 air-
bag system. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.

NOTE: The air inlet housing must be removed from
HVAC housing for service of the recirculation-air
door.

NOTE: LHD model shown in illustrations. RHD
model similar.

(1) Remove the HVAC housing assembly (Refer to

24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/HVAC HOUSING - REMOVAL).

(2) Remove the recirculation door actuator (Fig.

15) (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/RECIRCULATION DOOR
ACTUATOR - REMOVAL).

(3) Remove the recirculation door actuator wire

lead from the routing clip located on the lower air
inlet housing and position the wire lead aside.

(4) Disconnect the blower motor wire lead connec-

tor from the blower motor resistor or power module,
depending on application.

(5) Remove the one screw (from the top) that

secures the lower air inlet housing to the upper air
inlet housing.

(6) Remove the four screws (from the bottom) that

secure the lower air inlet housing to the upper air
inlet housing and remove the lower HVAC housing.

(7) Push the rubber blower motor wire lead grom-

met through the opening in the lower air inlet hous-
ing (Fig. 16).

(8) 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.

(9) Carefully cut the foam seal along the parting

line of the upper air inlet housing (Fig. 17). If the
seal is deformed or damaged, it must be replaced.

(10) Remove the three screws that secure the

upper air inlet housing to HVAC housing.

(11) Remove the upper air inlet housing and recir-

culation-air door from the HVAC housing.

(12) If required, remove the screw that secures the

recirculation-air door to the upper air inlet housing
and remove the air door.

Fig. 14 Retainers - Air Distribution Housing

1 - AIR DISTRIBUTION HOUSING
2 - SCREWS (4)
3 - TAB-AND-SLOT RETAINERS (2)
4 - HVAC HOUSING

Fig. 15 Lower Air Inlet Housing

1 - BLOWER MOTOR RESISTOR/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)

24 - 52

DISTRIBUTION - FRONT

HVAC HOUSING (Continued)

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