I appreciate the help... Well I tried that fix and it didn't work, my temp controller controls all the vents temp but the passenger side actuator I believe must be defective. I found the location of the actuator and there is no way to check voltage without removing the dash completely. I guess I have my work cut out for me.
Thanks
I have directed so many guys on how to fix this problem that my fingers are blue from typing. But here I go again.
The secret to solving this problem is
proper trouble-shooting. You cannot fix this problem until you know some variables. Instead of typing the entire procedure out again, I'll point you in the right direction. Once you complete the initial information gathering stage, then I'll explain how to resolve your issue.
Step 1. Attempt the recalibration of the HVAC. - You have completed this step and the problem still exist.
Step 2. Perform a evacuation and recovery of your R-134a (freon to you old guys). - What this will do is tell you EXACTLY how much R-134a is in your system. If there is too much or too little R-134a, your system will do weird things. Your year car should have exactly 0.68 kg (1.50 lb) of R-134a in it. You'll have to go to some place that has a ACR 2000 Air Conditioning Service Center machine (or similar), capable of doing this and getting you the readings that you need to know. Find a mom and pop shop that can do this. The dealer will rip you a new one on the cost. A mom and pop shop will charge you around $50 if they don't have to add any R-134a.
If they do have to add R-134a, then you have a leak. When they refill the system, make sure that they also add some green dye to the system so that you can locate the leak. Without the dye, you will never find the leak. Once you locate the leak (if any), then I can direct you on how to fix the leak.
Note: You say that the passenger's side is blowing only cold air. This is highly unusual for a R-134a problem because on a automobile HVAC system, the air usually defaults to heat if there is a refrigerant problem. The reason cars are designed to do this is because you can drive a car year round without AC, but you can't drive a car in cold climates without heat (you won't be able to defrost the windows for one). So the fact that your vent always blows cold makes me think that you have an actuator problem on the passenger's side. The thing is, the actuators in the 2001-2004's are not a common failure part. They did have an issue with the earlier models but not the ones in your car. Since the dash pad has to come off the car in order to replace the passenger's side actuator and is a fair amount of work (not so for the driver's side), you don't want to go there unless you have to. That's why you want to verify the refrigerant level before pulling the dash pad.
So your next step is to find out what your R-134a level is. Then we will take it from there. One more side note. On the dual climate control HVAC units, the passenger's side has their own temperature knob. Although it allows you to somewhat control the temps on that side of the car, it will not be a significant amount of change from what the driver's side is blowing. Some people are under the misconception that you can blow cold air out the driver's side and heat out the passenger's side at the same time. The only time that is possible is when there is a problem with your HVAC system.
