Chrysler Town, Dodge Caravan. Manual — part 511
(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 (MTC) or the front blower
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 diagnosis of the front
blower motor resistor. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS
-
FRONT/BLOWER
MOTOR RESISTOR - DIAGNOSIS AND TESTING).
If OK with ATC, use a DRBIII scan tool to diagnose
the front blower power module. Refer to the appropri-
ate 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 (Fig. 8).
24 - 44
DISTRIBUTION - FRONT
RS
BLOWER MOTOR (Continued)
Fig. 8 Blower Motor Noise/Vibration Diagnosis
RS
DISTRIBUTION - FRONT
24 - 45
BLOWER MOTOR (Continued)
REMOVAL
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING
THE
FOLLOWING
OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Disconnect the blower motor pigtail harness
connector from the connector receptacle of either the
blower motor resistor or power module, depending
how vehicle is equipped (Fig. 9).
(2) Remove the HVAC assembly from the vehi-
cle(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(3) Remove the two screws that secure the recircu-
lation door actuator and disengage the wire harness
from the routing clips molded into the bottom of the
lower air intake housing.
(4) Remove the one screw (from the top) that
secures the lower air intake housing to the upper air
intake housing.
(5) Remove the four screws (from the bottom) that
secures the lower air intake housing to the lower half
of the evaporator housing and the upper air intake
housing.
(6) Push the rubber grommet on the blower motor
pigtail wires through the hole in the lower intake air
housing (Fig. 10).
(7) Feed the blower motor pigtail wires and electri-
cal connector through the grommet hole in the lower
intake air housing.
(8) Relocate the recirculation air door as necessary
to access and remove the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing (Fig. 11).
(9) Gently flex the recirculation air door far
enough to remove the blower motor and blower wheel
from the blower housing in the lower half of the
evaporator housing.
INSTALLATION
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
Fig. 9 Lower Intake Air Housing
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION AIR DOOR ACTUATOR
3 - BLOWER MOTOR PIGTAIL WIRE CONNECTOR
4 - RUBBER GROMMET
5 - BLOWER MOTOR RESISTOR/POWER MODULE
6 - LOWER EVAPORATOR HOUSING
7 - UPPER INTAKE AIR HOUSING
8 - RECIRCULATION AIR DOOR
Fig. 10 Rubber Grommet - Typical
1 - BLOWER MOTOR PIGTAIL WIRE GROMMET
24 - 46
DISTRIBUTION - FRONT
RS
BLOWER MOTOR (Continued)
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING
THE
FOLLOWING
OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Gently flex the recirculation air door far
enough to position the blower motor and blower
wheel into the blower housing in the lower half of the
evaporator housing.
(2) Install and tighten the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing. Tighten the screws to
2 N·m (18 in. lbs.).
(3) Feed the blower motor pigtail wires and electri-
cal connector through the grommet hole in the lower
intake air housing and seat the rubber grommet.
(4) Position the recirculation door in the lower air
inlet housing and place in position.
(5) Install and tighten the four screws (from the
bottom) that secure the lower air intake housing to
the lower half of the evaporator housing. Tighten the
screws to 2 N·m (18 in. lbs.).
(6) Install and tighten the one screw that secures
the upper intake air housing to the lower intake air
housing. Tighten the screws to 2 N·m (18 in. lbs.).
(7) Install the recirculation actuator making cer-
tain that the splines are aligned and secure the
actuator with two screws and torque the to 2 N·m (18
in. lbs.). Route the wiring into the molded inn rout-
ing clips.
(8) Install the HVAC unit in the vehicle(Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - INSTALLATION).
(9) Connect the blower motor pigtail wire harness
electrical connector back into either the power mod-
ule or resistor receptacle.
(10) Run the Heater-A/C Calibration procedure(Re-
fer to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C
HEATER
CONTROL
-
STANDARD
PROCEDURE).
(11) Run the HVAC Control Cool down test(Refer
to 24 - HEATING & AIR CONDITIONING - DIAG-
NOSIS AND TESTING).
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.
Fig. 11 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RS
DISTRIBUTION - FRONT
24 - 47
BLOWER MOTOR (Continued)
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