lock CHRYSLER VOYAGER 1996 Service Manual

SLIDING DOOR LATCH/LOCK CONTROL
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sliding door stop bumper.
(3) Remove sound pad, if equipped.
(4) Remove latch/lock control cover (Fig. 113).
(5) With sliding door ajar, disengage clip holding
rear latch link to latch/lock control (Fig. 114) (Fig.
115).
(6) Place a flat head screw driver between metal
clip ears and bottom of link.
NOTE: Rotate screw driver to remove link.
CAUTION: Replace the latch/lock control if any of
the metal clips on the latch/lock control are bent or
broken. DO NOT attempt to repair the clips to retain
the links.
(7) Remove rear latch link from latch/lock control.
(8) Disengage clip holding outside door handle link
to latch/lock control (Fig. 115).
(9) Remove outside door handle link from latch/
lock control.
(10) Disengage clip holding inside door handle
bellcrank link to latch/lock control (Fig. 115).
(11) Separate inside door handle bellcrank link
from latch/lock control.
(12) Disengage clip holding lock cylinder link to
latch/lock control.
(13) Remove lock cylinder link from control.
(14) Disengage clip holding inside lock link to
latch/lock control.
(15) Remove inside lock link from control.
(16) Disengage lock tabs holding hold open latch
cable case to latch/lock control.
(17) Remove hold open latch cable ball end from
latch/lock control.
(18) Loosen bolts holding latch/lock control to slid-
ing door.
(19) If equipped, disconnect wire connector from
power door lock motor.
(20) Remove latch/lock from vehicle.
INSTALLATION
(1) Position latch/lock locking lever in unlocked
position.
(2) Engage rigging cam (Fig. 114).
(3) Place latch/lock in position on vehicle.
(4) If equipped, engage wire connector into power
door lock motor.
(5) Insert bolt heads into slots in sliding door
inner panel.
(6) Tighten bolts to hold latch/lock control to slid-
ing door.(7) Engage hold open latch cable ball end into
latch/lock control.
(8) Engage lock tabs to hold the hold open latch
cable case to latch/lock control.
(9) Insert lock cylinder link into control.
(10) Engage clip to hold lock cylinder link to latch/
lock control.
(11) Insert inside lock link into control.
(12) Engage clip to hold inside lock link to latch/
lock control.
(13) Lift clip for inside door handle bellcrank link
to top of slot in mechanism (Fig. 114).
(14) Engage clip to hold bellcrank link to latch/lock
control.
(15) Lower clip for outside door handle link to bot-
tom of slot in mechanism and engage link to clip
(Fig. 114).
NOTE: Move link rearward until movement stops
before engaging link to clip.
(16) Place rear latch link in position on control by
moving link rearward until movement stops.
(17) Engage clip to hold rear latch release link to
latch/lock control.
(18) Push inside lock link button downward to dis-
engage rigging cam.
(19) Verify sliding door operation.
(20) Install latch/lock cover.
(21) Install sound pad, if equipped.
(22) Install sliding door stop bumper.
(23) Install sliding door trim panel.
Fig. 113 Latch/Lock Cover
23 - 70 BODYNS
REMOVAL AND INSTALLATION (Continued)

SLIDING DOOR LOWER ROLLER ARM
REMOVAL
(1) Open sliding door.
(2) Mark outline of roller arm on sliding door
bracket to aid installation.
(3) Remove sliding door sill plate.
(4) Remove screws holding hold open latch to
lower roller arm.
(5) Separate hold open latch from lower arm.(6) Support sliding door on a suitable lifting device
with a padded upper surface. The door must be
moveable with lifting device in place.
(7) Remove bolts holding lower roller arm to slid-
ing door (Fig. 116).
(8) Remove roller arm from sliding door.
(9) Disengage roller arm from lower channel (Fig.
117).
(10) Remove roller arm from vehicle.
INSTALLATION
For installation, reverse the above procedures.
SLIDING DOOR LOWER ROLLER ARM BRACKET
REMOVAL
(1) Remove access hole plug.
(2) Open sliding door.
(3) Support sliding door on a suitable lifting
device.
(4) Remove lower roller arm.
(5) Mark outline of roller arm bracket on inside of
sliding door.
(6) Remove bolts holding lower roller arm bracket
to sliding door (Fig. 118).
(7) Remove lower roller bracket from vehicle.
Fig. 114 Sliding Door Latch/Lock Control Linkage
Fig. 115 Latch/Lock Control Link Removal
NSBODY 23 - 71
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place lower roller bracket in position on vehi-
cle.
(2) Align outline mark on inside of sliding door to
roller arm bracket.(3) Install bolts holding lower roller arm bracket to
sliding door.
(4) Install lower roller arm.
(5) Remove lifting device.
(6) Verify sliding door operation.
(7) Install access hole plug.
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sliding door stop bumper.
(3) Remove watershield as necessary to access out-
side release handle fasteners.
(4) Remove latch/lock control cover.
(5) Disengage clip holding outside door handle
linkage to door handle.
(6) Separate linkage from outside door handle.
(7) Separate linkage from latch/lock control.
(8) Remove nuts holding outside door handle to
outer door panel (Fig. 119).
(9) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts to hold outside door handle to
outer door panel.
(3) Insert linkage into outside door handle.
(4) Engage clip to hold linkage to outside door
handle.
(5) Engage rigging cam to latch/lock control mech-
anism.
(6) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(7) Verify sliding door operation. Adjust as neces-
sary.
(8) Install latch/lock cover.
(9) Install watershield.
(10) Install sliding door stop bumper.
(11) Install sliding door trim panel.
Fig. 116 Sliding Door Lower Roller Arm
Fig. 117 Sliding Door Roller Arm Channel
Fig. 118 Sliding Door Lower Roller Arm Bracket
Fig. 119 Sliding Door Outside Latch Release Handle
23 - 72 BODYNS
REMOVAL AND INSTALLATION (Continued)

SLIDING DOOR REAR LATCH
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove water shield as necessary.
(3) Open sliding door to the ajar position.
(4) Disengage clip holding linkage to rear latch.
(5) Remove screws holding rear latch to sliding
door end frame (Fig. 120).
(6) Remove sliding door rear latch from door
through rear access hole.
INSTALLATION
NOTE: The screws attaching the rear latch to slid-
ing door end frame have locking patch on the
threads. Screws must be replaced during installa-
tion.
(1) Position sliding door rear latch on door through
rear access hole.
(2) Install screws to hold rear latch to sliding door
end frame.
(3) Engage clip to hold linkage to rear latch.
(4) Verify sliding door operation. Adjust as neces-
sary.
(5) Install water shield.
(6) Install sliding door trim panel.
SLIDING DOOR SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to
sliding door opening sill.
(2) Disengage hooks holding outside edge of sill
plate to door sill (Fig. 121).
(3) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Engage hooks to hold outside edge of sill plate
to door sill.
(3) Align guide pins to holes in door sill.
(4) Engage hidden clips to hold sill plate to sliding
door opening sill.
SLIDING DOOR STABILIZER
REMOVAL
(1) Open sliding door.
(2) Remove screws holding stabilizer to door end
frame (Fig. 122).
(3) Remove stabilizer from vehicle.
INSTALLATION
(1) Place stabilizer in position on vehicle.
NOTE: Loose install screws first. Fit should be
snug but free to move when closing door to align to
body half stabilizer.
(2) Install screws to hold stabilizer to door end
frame.
(3) Open door and final torque screws.
(4) Verify sliding door operation.
Fig. 120 Sliding Door Rear Latch
Fig. 121 Sliding Door Sill Plate
Fig. 122 Sliding Door Stabilizer
NSBODY 23 - 73
REMOVAL AND INSTALLATION (Continued)

(5) If necessary, install screw from inside ash
receiver bezel on left sliding door trim panel.
(6) Install sliding door upper frame molding.
SLIDING DOOR UPPER ROLLER
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw holding upper stop bracket to
upper roller bracket (Fig. 127).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper roller bracket on sliding
door.
(6) Remove bolts holding upper roller to sliding
door (Fig. 128).
(7) Remove upper roller from door.
(8) Slide roller out of rear end of roof rail channel.
(9) Remove upper roller from vehicle.
INSTALLATION
(1) Place upper roller in position on vehicle.
(2) Slide roller into rear end of roof rail channel.
(3) Place upper roller in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
(5) Install bolts to hold upper roller to sliding door.
(6) Remove padded block from between sliding
door and roof rail.
(7) Place stop bracket in position on vehicle.
(8) Install screw to hold upper stop bracket to
upper roller bracket.(9) Verify sliding door alignment and operation.
Adjust as necessary.
SLIDING DOOR WEATHER-STRIP
REMOVAL
(1) Open sliding door.
(2) Remove door opening sill plate.
(3) Loosen B-pillar trim covers.
(4) Loosen quarter panel trim panels.
(5) From splice at the bottom center of door open-
ing, pull weather-strip from pinch flange around door
opening.
INSTALLATION
For installation, reverse the above procedures.
STICK-ON BODY SIDE MOLDING
REMOVAL
Refer to (Fig. 129), (Fig. 130), (Fig. 131), (Fig. 132)
or (Fig. 133) for proper location of fasteners holding
the molding to the wheelhouse lip and rocker panels.
(1) Warm the affected stick-on molding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun.
Fig. 126 Sliding Door Trim Panel Screws
Fig. 127 Sliding Door Upper Stop
Fig. 128 Sliding Door Upper Roller
NSBODY 23 - 75
REMOVAL AND INSTALLATION (Continued)

UPPER C-PILLAR TRIM
REMOVAL
(1) Remove quarter trim bolster.
(2) Remove seat belt turning loop from height
adjuster.
(3) Remove screw holding C-pillar trim panel to
C-pillar on right side of SWB vehicle.
(4) Disengage hidden clips holding trim to upper
C-pillar.
(5) Remove upper C-pillar trim from vehicle.
INSTALLATION
(1) Place upper C-pillar trim in position on vehicle.
(2) Engage hidden clips to hold trim to upper
C-pillar.
(3) Install screw to hold C-pillar trim panel to
C-pillar on right side of SWB vehicle.
(4) Install seat belt turning loop onto height
adjuster. Tighten all seat belt bolts to 39 N´m (29 in.
lbs.) torque.
(5) Install quarter trim bolster.
ADJUSTMENTS
SLIDING DOOR ADJUSTMENTS
PRELIMINARY CHECKS
(1) Close sliding door, visually checking C-post
striker alignment entry into latch. Striker at this
point must not affect alignment.(2) On vehicles with left sliding doors, check the
fuel door blocker striker entry into latch. Striker at
this point must not affect alignment.
(3) Check C-post and B-post for door to aperture
gaps and door to door gaps. All gaps should be 5 mm
61 mm.
(4) C
heck door for height using character lines as a
reference. Also check roof contour as a controlling factor.
UP/DOWN ADJUSTMENT
(1) Visually inspect the sliding door for fitting low
at the rear of the door by checking the alignment of
the belt line of the door to quarter panel.
(2) Fully open the sliding door.
(3) Verify that all center hinge bolts are tight.
(4) Adjust the rear of the sliding door up by turn-
ing the center hinge bolt clockwise (Fig. 137).
(5) Close the door and check the sliding door align-
ment.
(6) Readjust the center hinge if necessary to obtain
alignment between the belt line of the sliding door
and quarter panel.
(7) Fully open door and apply thread lock nut onto
the center hinge bolt. Tighten nut until till it butts
up against the welded nut on the center hinge.
Tighten nut to 15 N´m (130 in. lbs.). It may be nec-
essary to hold the center hinge bolt to prevent it
from turning while tightening nut.
(8) Verify alignment. Re-adjust as necessary.
FORE/AFT ADJUSTMENT
(1) Check height of sliding door at the B-post and
C-post to determine which area is contributing the
greatest to the incorrect gaps.
(2) If the sliding door is high at the C-post;
(a) Open the door to mid-point of travel.
Fig. 136 Upper B-pillar Trim Cover
Fig. 137 Sliding Door Center Hinge
23 - 80 BODYNS
REMOVAL AND INSTALLATION (Continued)

BODY
CONTENTS
page page
BODY COMPONENT SERVICE............... 3 SEATS .................................. 1
SEATS
INDEX
page page
REMOVAL AND INSTALLATION
BENCH SEAT BACK COVER................ 2
HEAD RESTRAINT ESCUTCHEON........... 1HEAD RESTRAINT SLEEVE................. 2
HEAD RESTRAINT........................ 1
REMOVAL AND INSTALLATION
HEAD RESTRAINT
REMOVAL
(1) Lift head restraint to top of travel.
(2) Depress lock button on side of sleeve at top of
seat back (Fig. 1).
(3) Pull head restraint from top of seat back.
INSTALLATION
(1) Position head restraint to seat.
(2) Depress lock button on side of sleeve at top of
seat back.
(3) Insert head restraint into sleeves at top of seat
back.
HEAD RESTRAINT ESCUTCHEON
REMOVAL
(1) Remove head restraint from seat.
(2) Remove escutcheon from head restraint sleeve
(Fig. 2).
(3) Remove head restraint retainer from sleeve.
(4) Separate escutcheon and retainer from vehicle.
INSTALLATION
(1) Position escutcheon and retainer to seat.
(2) Install retainer to sleeve.
(3) Install escutcheon to sleeve.
(4) Install head restraint to seat.
Fig. 1 Head RestraintÐBucket Seat
NS/GSBODY 23 - 1

HEAD RESTRAINT SLEEVE
REMOVAL
(1) Remove head restraint.
(2) Disengage closure holding bottom of trim cover
together.
(3) Reach under trim cover through opening at
bottom of seat back.
(4) Pinch retainer barbs on middle of head
restraint sleeve together (Fig. 3).
(5) Pull head restraint sleeve upward and out the
top of the seat back frame guide tube.
INSTALLATION
(1) Insert head restraint sleeve into guide tube at
top of seat back.
(2) Align locator rib to locator rib notch in guide
tube (Fig. 4).(3) Push head restraint sleeve downward until
retainer clicks into lock position.
(4) Engage closure to hold bottom of trim cover
together.
(5) Install head restraint.
BENCH SEAT BACK COVER
REMOVAL
(1) Remove screws holding the bottom of the bench
seat back cover to the seat frame (Fig. 5).
(2) Disengage hooks holding top of seat back cover
to seat back frame.
(3) Separate seat back cover from seat.
INSTALLATION
(1) Place seat back cover in position on seat.
(2) Engage hooks to hold top of seat back cover to
seat back frame.
(3) Install screws to hold bottom of bench seat
back cover to seat frame.
Fig. 2 Head Restraint Escutcheon and Retainer
Fig. 3 Head Restraint Sleeve Removal
Fig. 4 Head Restraint Sleeve Installation
Fig. 5 Bench Seat Back Cover
23 - 2 BODYNS/GS
REMOVAL AND INSTALLATION (Continued)

HEATING AND AIR CONDITIONING
CONTENTS
page page
FRONT HEATING AND AIR CONDITIONING
SYSTEM............................... 1REAR HEATING AND AIR CONDITIONING
SYSTEM.............................. 41
FRONT HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 2
SAFETY PRECAUTIONS AND WARNINGS...... 2
DESCRIPTION AND OPERATION
A/C PRESSURE TRANSDUCER.............. 2
A/C SERVICE PORTS..................... 2
AIR DISTRIBUTION DUCTS................. 2
COMPRESSOR HIGH-PRESSURE RELIEF
VALVE................................ 3
CONDENSATE DRAIN..................... 3
ENGINE COOLING SYSTEM REQUIREMENTS . . 3
EVAPORATOR PROBE..................... 3
HANDLING TUBING AND FITTINGS........... 3
HVAC CONTROL MODULE................. 4
REAR BLOWER SPEED SWITCH............ 3
SIDE DOOR HEATER A/C OUTLETS.......... 4
SIDE WINDOW DEMISTER................. 4
SYSTEM AIRFLOW....................... 4
SYSTEM OIL LEVEL...................... 5
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST................ 12
A/C PRESSURE TRANSDUCER............. 12
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST...................... 6
BLOWER MOTOR AND WHEEL ASSEMBLY.... 13
COMPRESSOR CLUTCH/COIL.............. 13
COMPRESSOR NOISE DIAGNOSIS.......... 13
EXPANSION VALVE...................... 13
HEATER PERFORMANCE TEST............ 15
HVAC CONTROL DIAGNOSTIC CONDITIONS . . . 9
SYSTEM CHARGE LEVEL TEST............ 16SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM........ 17
EVACUATING REFRIGERANT SYSTEM....... 18
R-134a REFRIGERANT................... 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS............................ 19
SYSTEM LEAK CHECKING................ 19
THERMOCOUPLE PROBE................. 19
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER............. 20
A/C SERVICE PORTS.................... 20
BLEND-AIR DOOR ACTUATOR............. 20
BLOWER MOTOR AND WHEEL ASSEMBLY.... 21
BLOWER MOTOR RESISTOR BLOCK........ 21
BLOWER MOTOR WHEEL................. 22
COMPRESSOR CLUTCH/COIL.............. 23
COMPRESSOR......................... 23
CONDENSER ASSEMBLY................. 25
DISCHARGE LINE....................... 26
EVAPORATOR PROBE.................... 27
EXPANSION VALVE...................... 28
FILTER-DRIER ASSEMBLY................. 28
HEATER A/C UNIT HOUSING............... 29
HEATER CORE......................... 30
HEATER HOSES........................ 31
LIQUID LINE........................... 32
MODE DOOR ACTUATOR................. 32
RECIRC DOOR ACTUATOR................ 34
SIDE WINDOW DEMISTER DUCTS.......... 33
SUCTION LINE.......................... 33
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION........... 34
NSHEATING AND AIR CONDITIONING 24 - 1

The High Side service port is a two piece port and
is serviceable. The Low Side service port is not ser-
viceable, the suction line would have to be replaced.
REAR BLOWER SPEED SWITCH
The rear blower speed switch controls the rear
blower with the choice of low and high speeds. When
the switch is on it allows the blower speed switch
located on the rear headliner to control rear blower
speed. This switch will override the rear headliner
blower switch. For operation instructions refer to the
Owner's Manual. The rear blower speed switch is
serviced separately from the A/C control module. For
service procedures, refer to Group 8E, Instrument
Panel And Gauges.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The High Pressure Relief Valve prevents damage
to the air conditioning system if excessive pressure
develops. Excessive pressure can be caused by con-
denser air flow blockage, refrigerant overcharge, or
air and moisture in the system.The high pressure relief valve vents only a small
amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the
refrigerant is conserved in the system. The valve is
calibrated to vent at a pressure of 3450 to 4140 kPa
(500 to 600 psi). If a valve has vented a small
amount of refrigerant, it does not necessarily mean
the valve is defective.
The High Pressure Relief Valve is located on the
compressor manifold at the discharge passage.
NOTE: Special effort must be used to keep all
R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a
reliability problem with the compressor.
CONDENSATE DRAIN
Condensation from the evaporator housing is
drained through the dash panel and on to the
ground. This drain must be kept open to prevent
water from collecting in the bottom of the housing.
If the drain is blocked condensate cannot drain,
causing water to back up and spill into the passenger
compartment. It is normal to see condensate drain-
age below the vehicle.
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain ample temperature levels from the
heating-A/C system, the cooling system must be in
proper working order. Refer to Group 0, Lubrication
and Maintenance or Group 7, Cooling System of this
manual.
The use of a bug screen is not recommended. Any
obstructions forward of the condenser can reduce the
effectiveness of the air conditioning system.
EVAPORATOR PROBE
The Evaporator probe is located on the HVAC. The
probe prevents evaporator freeze-up by signaling the
Powertrain Control Module to cycle the compressor
ON and OFF. The probe monitors the temperature of
the refrigerant after expansion.
The evaporator probe is inserted into the evapora-
tor between the coils. The probe is a sealed unit and
cannot be adjusted or repaired. It must be replaced if
found defective.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
Fig. 1 A/C Pressure Transducer
Fig. 2 Valve Service Ports
NSHEATING AND AIR CONDITIONING 24 - 3
DESCRIPTION AND OPERATION (Continued)