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DESCRIPTION & OPERATION Heating and ventilation system is a blend type system. A heater control valve is not used. Coolant flows unrestricted through heater core. Interior temperature is regulated by a blend door which controls amount of air flowing through heater core. Blend door is operated by a cable connected to temperature control knob. Three knobs are used to control blower speed, air temperature, and air distribution. Fresh air blower has 4 speeds. Blower motor resistor is located on blower motor housing. ADJUSTMENTS MAIN SHUTOFF FLAP CABLE Install heater control panel. Adjust blower control knob to stop at position “0″. Connect main shutoff flap cable (Black sleeve) to main shutoff flap lever. Push lever in direction of arrow until it stops. See Fig. 1. Hold lever in this position, and install cable retaining clip. TEMPERATURE FLAP CABLE Install heater control panel. Adjust temperature control knob to full cold. Connect temperature flap cable (Blue sleeve) to temperature flap lever. Push lever in direction of arrow until it stops. See Fig. 2. Hold lever in this position, and install cable retaining clip. Fig. 2: Adjusting Temperature Flap Cable Courtesy of Volkswagen United States, Inc. FOOTWELL/DEFROST FLAP CABLE Install heater control panel. Adjust airflow distribution knob to defrost position (against stop). Connect footwell/defrost flap cable (Black sleeve) to footwell/defrost flap lever. Push lever in direction of arrow until it stops. See Fig. 3. Hold lever in this position, and install cable retaining clip. Fig. 3: Adjusting Footwell/Defrost Flap Cable

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1. Disconnect the electrical connector (3). 2. Remove the blower motor resistor mounting screws (1). 3. Remove the blower motor resistor (2) from the blower case. 2. Install the blower motor resistor mounting screws (1). Tighten Tighten the screws to 1.9 N.m (17 lb in). 3. Connect the electrical connector (3). Removal Procedure (C60) 1. 2. 3. 4. 5. Remove the A/C control relay bracket with the relay. Remove the blower resistor harness. Remove the stud from the IP, if necessary. Remove the blower motor resistor mounting screw. Cut the access cover from the case. Cut all four sides of the cover in order to remove the three attaching screws. Use a sharp utility knife in order to cut the case. Make the cuts straight and clean. The access cover must be reinstalled and is visible to the customer.

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ISSUE Some vehicles built between 5/1/2001 and 12/15/2003 may exhibit water in the blower case or on the passenger side floor, an inoperative climate control blower motor, a motor that operates on high speed only, and/or a blower motor resistor failure. ACTION Inspect and seal cowl area and install Rain-Hat Extension Seal. Inspect and replace blower motor and/or blower motor resistor if there is evidence of water/corrosion. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Access blower motor and resistor per the Workshop Manual Sections 412-02 and 412-04. Inspect for evidence of water/corrosion. If water/corrosion are found or parts have failed, replace per Workshop Manual (blower motor 1F1Z-19805-AA and resistor F6DZ-19A706-AA). 2. Visually inspect the Cowl Vent Screen located under the RH windshield wiper to verify if the screen is fully seated. Inspect the rubber seal on the vent screen which should be fully seated against the windshield. If the cowl vent screen is not fully seated and appears warped, it must be replaced (4F1Z-54018A16-BAA). Remove the cowl vent screen per the Workshop Manual Section 412-01 Pollen Filter Removal and inspect the cabin filter to confirm it is fully seated. Re-seat the filter as necessary. Inspect rain-hat base to make sure it is secure and sealed to the body. Reposition and reseal as necessary using Clear Silicone Rubber TA-32. Remove the foam sealant expulsion at lower front outboard corner base of the rain-hat (Figure 1).

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SUBJECT: Front HVAC Blower Motor Resistor Connector Service MODELS: 1996 – 1997 (NS) Town & Country/Caravan/Voyager 1996 – 1997 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The front Heater/Ventilation/Air Conditioning (HVAC) blower motor is inoperative; is inoperative on one or more speeds; or operates only on “HIGH” speed. DIAGNOSIS: Visually inspect the front HVAC blower motor resistor and connector terminals for corrosion. If corrosion is discovered, perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves replacing the blower motor resistor and wiring connector with revised parts. 1. If equipped, remove the bracket on the A/C line from the right side strut tower mounting stud. 2. Obtain the revised front blower motor resistor, p/n 04677180AB, (and wiring repair components if they will be required). Examine the integral retainer clips of the resistor so it is understood what/where to push in on to release the resistor from the dash panel. NOTE : DO NOT TRY TO PULL THE RESISTOR OUT OF THE DASH PANEL WITHOUT RELEASING THE CLIPS, OTHERWISE RETENTION TABS IN THE DASH PANEL WILL BE BENT MAKING IT VERY DIFFICULT TO REMOVE THE RESISTOR FROM THE CAVITY IN THE DASH PANEL.

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To prevent system contamination, whenever the evaporator core is replaced, also replace the receiver/drier. NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle; see—– 07-10 A/C EVAPORATOR / CONDENSER CORE ONVEHICLE LEAK TEST . 1. Remove the evaporator core housing. See 07-11 EVAPORATOR CORE HOUSING REMOVAL / INSTALLATION . 2. Transfer the components from the old evaporator core housing to the new evaporator core housing. 3. Install the evaporator core housing. See 07-11 EVAPORATOR CORE HOUSING REMOVAL / INSTALLATION . 1. Disconnect the blower motor and blower motor resistor electrical connectors. 2. Disconnect the heater hoses. a. Using suitable tools, clamp-off the heater hoses. b. Release the clamps and disconnect the heater hoses. 1. Detach the pin-type retainer and position aside the windshield washer hose. 2. Disconnect the vacuum supply hose near the evaporator core housing. 3. Disconnect the condenser to evaporator line spring lock coupling from the evaporator core inlet. See 07-10 SPRING LOCK COUPLING . • Discard the O-ring seals. NOTE: The following step is performed at the lower passenger side dash panel, inside the passenger compartment.Disconnect the vacuum hose connector and remove the nut.