CHRYSLER VOYAGER 2001 Service Manual

Fig. 1 CABIN HEATER PIPES
1 - HEATER CORE INTAKE PIPE
2 - HEATER CORE RETURN PIPE
3 - A/C LINES
4 - A/C EXPANSION VALVE5 - A/C EXPANSION VALVE GROUND WIRE
6 - CABIN HEATER RETURN PIPE
7 - CABIN HEATER INTAKE PIPE
8 - CABIN HEATER PIPES RETAINING NUT
RGHEATING & AIR CONDITIONING24a-3
HEATER PIPES - DIESEL SUPPLEMENTAL HEATER (Continued)

REFRIGERANT
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL 2.5L DIESEL
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)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: The proper amount of R-134a refrigerant for
the refrigerant system in this model is:
²Single or Dual Zone (Front Unit Only - 2.5L Die-
sel) ± 0.91 kilograms (2.00 pounds or 32 ounces)
²Single or Dual Zone (Front Unit Only) - 0.96
kilograms (2.13 pounds or 34 ounces)
²Three Zone (Front and Rear Units) - 1.31 kilo-
grams (2.88 pounds or 46 ounces)
The procedure that follows should be used to deter-
mine whether the refrigerant system contains the
proper refrigerant charge. Symptoms of an improper
refrigerant charge (low) include: poor air conditionerperformance, fog emitted from the air conditioner out-
lets, a hissing sound from the expansion valve/evapo-
rator area. There are two different methods with
which the refrigerant charge level may be tested:
²Using a DRBIIItscan tool, a thermocouple and
the Charge Determination Chart (Fig. 3). Refer to
the appropriate diagnostic information.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 3).
A temperature probe is required to measure liquid
line temperature. The clamp-on, Type K thermocou-
ple temperature probe used in this procedure is
available through the DaimlerChrysler Professional
Service Equipment (PSE) program. This probe (PSE
#66-324-0014 or #80PK-1A) is compatible with tem-
perature-measuring instruments that accept Type K
thermocouples, and have a miniature connector
input. Other temperature probes are available
through aftermarket sources; however, all references
in this procedure will reflect the use of the probe
made available through the PSE program.
In order to use the temperature probe, a digital ther-
mometer will also be required. If a digital thermometer
is not available, an adapter is available through the
PSE program that will convert any standard digital
multimeter into a digital thermometer. This adapter is
designed to accept any standard Type K thermocouple.
If a digital multimeter is not available, this tool is also
available through the PSE program.
NOTE: When connecting the service equipment
couplings to the refrigerant system service ports,
be certain that the valve of each coupling is fully
closed. This will reduce the amount of effort
required to make the connection.
(1) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set or a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 to the refriger-
ant system.
(2) Attach a clamp-on thermocouple to the liquid
line. The thermocouple must be placed as close to the
A/C pressure transducer as possible to accurately
observe liquid line temperature.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run at idle under the following condi-
tions for five minutes.
(a) Front windows are open.
(b) Transaxle in Park.
(c) Front heater-A/C controls set to outside air,
full cool, panel mode, blower high, and compressor
engaged.
(d)
If the vehicle is so equipped, the rear heater-
A/C controls must be set to full cool and blower high.
Fig. 2 AIR INTAKE AND HEATER PIPE ASSEMBLY
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24a - 4 HEATING & AIR CONDITIONINGRG
HEATER PIPES - DIESEL SUPPLEMENTAL HEATER (Continued)

(4) Raise the liquid line (discharge) pressure to
about 1793 kPa (260 psi) by placing a piece of card-
board over part of the front side of the condenser. To
place the cardboard properly, remove the upper radi-
ator sight shield from the front fascia. Cover only
enough of the condenser to raise and maintain the
liquid line pressure at the specified level.
(5) Observe the liquid line (discharge) pressure
and liquid line temperature. Using the Charge Deter-
mination Chart (Fig. 3), determine whether the
refrigerant system is operating within the Proper
Charge Range.
(a) If the refrigerant system is operating in the
Undercharged area of the chart, add 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant to
the system.
(b) If the refrigerant system is operating in the
Overcharged area of the chart, reclaim 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant from
the system.
(6) Recheck the system charge level following each
refrigerant adjustment. Continue this process until
the system readings are in the Proper Charge Range
area on the Charge Determination Chart (Fig. 3).DIESEL SUPPLEMENTAL
HEATER - DCHA
DESCRIPTION
Vehicles equipped with the optional diesel engine are
also equipped with a supplemental heater unit. This
unit is mounted under the vehicle and operates similar
to an oil fired furnace. The heater burns small
amounts of fuel to provide additional heat to the cool-
ant. Coolant is routed from the engine, to the supple-
mental heater, and then to the front heater core. This
provides additional heat to the passenger compart-
ment. The system is interfaced to the vehicles on-board
computer systems and DRB-III diagnostics.
Fig. 3 Charge Determination Chart, Ambient Test Condition 85ÉF
RGHEATING & AIR CONDITIONING24a-5
REFRIGERANT (Continued)

OPERATION
The supplemental heater unit is activated via the
temperature slide control or knob on the vehicle HVAC
control unit. If the control slide or knob is moved to or
above the upper set point the heater is activated. The
unit can operate in a full or partial load range as well
as an idle mode all dependent on the engine coolanttemperature. The heater unit will also turn off if the
HVAC temperature control is lowered to less than the
lower set point. The heater unit can take up to three
minutes to completely shut down when either the
heater temperature is set below the lower set point or
the vehicle ignition is shut down.
DIAGNOSIS AND TESTING - DIESEL SUPPLEMENTAL HEATER - DCHA
The following table lists possible fault symptoms of
diesel fueled heaters.
SYMPTOM POSSIBLE CAUSES
Smell of diesel fuel Check heater system integration in vehicle's fuel system. Check fuel
lines for leakage, kinks or obstructions. If OK, Inspect the inlet muffler,
drain as necessary. Re-test the unit and re-inspect. Inspect the
exhaust tube and heater unit for the presence of external fuel. If a
volume is observed on the unit or in the exhaust tube or after draining
and testing. Remove heater unit from vehicle and repair or replace
components as required.
Heater does not achieve full load
operation.Check heater operation with DRB-III and replace components as
required.
Continuous white smoke from heater
exhaust during combustion operation.Check heater operation with DRB-III and replace components as
required. White smoke is typical in extreme weather conditions.
Heater can not be switched off. Check heater operation with DRB-III and replace components as
required.
Heater does not operate. Diagnosis cabin heater ECU using the DRB-III and the procedures
listed in Vehicle Performance under Cabin Heater Diagnosis in Group
18.
Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an
extremely sweet smell.Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is
an internal heater leak and unit should be inspected and components
should be replaced as required.
Loss of fuel (dripping). Check heater system integration in vehicles fuel system. Check fuel
line connection for leakage. If OK there is an internal leak and unit
should be inspected and replaced as required.
EXHAUST TUBE
REMOVAL
WARNING: THERE IS A POTENTIAL DANGER OF
SKIN BURNS AS THE HEATER AND ITS COMPO-
NENTS MAY BE VERY HOT. MAKE SURE THE
HEATER IS ALLOWED TO COOL DOWN BEFORE
ANY SERVICE WORK IS ATTEMPTED.
WARNING: THERE IS A POTENTIAL DANGER OF
SKIN BURNS AS THE EXHAUST SYSTEM MAY BE
VERY HOT. MAKE SURE THE EXHAUST SYSTEM ISALLOWED TO COOL DOWN BEFORE ANY SERVICE
WORK IS ATTEMPTED ON THE CABIN HEATER.
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 4).
(3) Remove the clamp at the flexible pipe connec-
tion and the heater unit housing (if required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
24a - 6 HEATING & AIR CONDITIONINGRG
DIESEL SUPPLEMENTAL HEATER - DCHA (Continued)

INSTALLATION
(1) Install the flexible exhaust pipe to the heater
unit. Tighten mounting clamp.
(2) Position the steel exhaust pipe to the flexible
exhaust and install and tighten the mounting clamp.
(3) Install the three exhaust pipe screws, adjust
pipe placement as needed and tighten the screws.
(4) Install the clamp to connect the steel exhaust
pipe to the flexible exhaust pipe and tighten clamp.
(5) Check exhaust pipe exhaust end placement and
make any final adjustments.
(6) Lower vehicle from lift.
FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the heater
from the vehicles fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental heater electronic control module. Thepump supplies diesel fuel from the fuel tank to the
heater unit.
REMOVAL
The dosing pump is serviceable without removing
the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line.(Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 5).
(2) Disconnect the fuel line between the dosing
pump and the heater unit.
NOTE: Position and retain heater fuel line to pre-
vent fuel leakage while servicing dosing pump.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(3) Disconnect the electrical connector to the fuel
pump by depressing the integral spring and pulling
the connector away from the pump.
(4) Remove the dosing pump from the rubber iso-
lation.
Fig. 4 Diesel Cabin Heater Exhaust System
1 - Mounting screws (3)
2 - Steel heater exhaust pipe
3 - Exhaust clamp (2)4 - Flexible heater exhaust pipe
5 - Heater and heater shield
6 - Exhaust pipe mounting clips (3)
RGHEATING & AIR CONDITIONING24a-7
EXHAUST TUBE (Continued)

INSTALLATION
(1) Mount the rubber isolation back onto the
splash shield mounting flanges at two locations.
(2) Connect fuel lines to the dosing pump and the
heater unit. The connectors should point towards the
heater fuel line.
(3) Use aviation style clamps to attach the hose to
the fuel pump nipples(Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/FUEL LINE -
INSTALLATION).
(4) Connect the electrical connector to the fuel
pump by depressing the integral spring and pushing
the connector towards the dosing pump. Pull the con-
nector towards the heater to verify the installation.
(5) Verify function of the heater.
FUEL LINE
STANDARD PROCEDURE - CLEANING
(1) Remove the cabin heater fuel line(Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - REMOVAL).
(2) With cabin heater line removed from vehicle
place a shop cloth on the fuel tank end of the fuelline to catch any residue, then apply a small amount
of air pressure to the other end of the fuel line.
(3) Check to see if air pressure is coming from the
tank end of the line. If pressure is flowing unre-
stricted the line is clean.
(4) If the line shows any signs of being restricted
after air pressure is applied, then the fuel line should
be replaced.
(5) Install the cabin heater line(Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - INSTALLATION).
(6) Verify function of the heater.
REMOVAL
(1) Elevate vehicle on a lift taking note of the
heater exhaust tube flexible section.
(2) Remove clamps on dosing pump end of fuel line
and separate line from pump (Fig. 6).
NOTE: Have an approved fuel holding device ready
to capture any diesel fuel that drains from fuel line
or heater unit.
(3) Remove clamp from fuel line at fuel tank con-
nection and separate line from tank.
(4) Remove any retaining clips and remove line
from vehicle.
Fig. 5 Dosing Pump Fuel Line
1 - Fuel Line
2 - Retaining Clamps3 - Dosing Pump
4 - Heater Unit Air Intake Pipe
24a - 8 HEATING & AIR CONDITIONINGRG
FUEL DOSING PUMP (Continued)

INSTALLATION
WARNING: DO NOT OPERATE THE DCHA IN AN
ENCLOSED AREA SUCH AS A GARAGE THAT
DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA'S EXHAUST WHEN
OPERATING THE DCHA. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY OR DEATH.
WARNING: ALLOW THE DCHA ASSEMBLY TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR/REPLACEMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
WARNING: VERIFY THAT ALL DCHA FUEL LINES
ARE SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING THIS PRO-
CEDURE.
NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle's fuel tank before performing this
procedure. Add fuel, if necessary.(1) Install heater fuel supply line to vehicle and
install in fuel line retainers
(2) Install fuel line connection at fuel tank and
tighten connection.
(3) Install fuel line at Dosing Pump and tighten
connection.
(4) Lower vehicle from lift.
NOTE: Failure to prime the Dosing Pump after
draining the DCHA fuel line will prevent DCHA
heater activation during the first attempt to start the
heater. This will also set a Diagnostic Trouble Code
(DCT) in the DCHA Control's memory. do not per-
form the Dosing Pump Priming procedure if an
attempt was made to start the DCHA without prim-
ing the Dosing Pump first. This will put excess fuel
in the DCHA Heater Module and cause smoke to
emit from the DCHA exhaust pipe when heater acti-
vation occurs.
(5) Connect the DRBIIItto the Diagnostic Link
Connector.
(6) Turn the ignition to the on position.
Fig. 6 Dosing Pump Fuel Line
1 - Fuel Line
2 - Retaining Clamps3 - Dosing Pump
4 - Heater Unit Air Intake Pipe
RGHEATING & AIR CONDITIONING24a-9
FUEL LINE (Continued)

NOTE:Do not activate the Dosing Pump Prime more
than one time. This will put excess fuel in the DCHA
Heater Module an cause smoke to emit from the
DCHA exhaust pipe when heater activation occurs.
NOTE: A clicking noise heard coming from the Dos-
ing Pump indicates that the pump is operational.
(7)
With the DRBIIItin Cabin Heater, select Sys-
tem Tests and Dosing Pump Prime. Allow the Dosing
Pump to run for the full 45 second cycle time. When
the 45 second cycle is complete, press Page Back on
the DRBIIItkey pad to exit the Dosing Pump Prime.
The Dosing Pump priming procedure is now complete.
HEATER UNIT
REMOVAL
WARNING: ALLOW THE DCHA TO COOL BEFORE
PERFORMING A COMPONENT INSPECTION/REPAIR
OR REPLACEMENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: ALLOW THE EXHAUST SYSTEM TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR OR REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
(1) Elevate the vehicle on a hoist/lift taking note of
heater exhaust tube flexible section.
(2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the heater and the hose and
tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board cross member at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe board cross member and
rail.
(7) Remove the wiring harness from the toe board
cross member(Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel fill cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(9) Loosen the two M8 fasteners at the rail. Take
care to notice that the exhaust tube bracket tab is on
top of the heater bracket.
(10) Remove the heater exhaust tube flex section
from the exhaust tube by loosening the M6 bolt of
the clamp assembly. Remove the hose from the
exhaust tube. Removal of the rail tube assembly may
aid in this service operation.(Refer to 24 - HEATING
& AIR CONDITIONING/CABIN HEATER/EXHAUST
TUBE - REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to cross member.
(12) Loosen the remaining M6 and M8 fasteners
which mount the exhaust tube assembly to the vehi-
cle.
(a) Install a suitable cabin heater support device
under the cabin heater and secure the cabin heater
to the device.
(13) Loosen the remaining three M6 fasteners to
the cross members.
(14) Remove the loosened fasteners that support
the heater while supporting the weight of the heater.
(15) Swing the unit mounting bracket from
between the exhaust bracket and rail mounting loca-
tion. Drain any residual coolant from the heater unit.
(16) Lower the cabin heater and remove from the
supporting device and place on a suitable work area.
INSTALLATION
(1) Install the unit mounting bracket between the
exhaust bracket and the rail mounting location.
(2) Install the fasteners that support the heater
while supporting the weight of the heater.
(3) Install the three M6 fasteners to the cross
members. Tighten the M6 fasteners to 7 Nm (5 ft.
lbs.).
(4) Tighten the remaining M6 fasteners to 7 Nm (5
ft. lbs.) and the M8 fasteners to 23 Nm (17 ft. lbs.)
which mount the exhaust tube assembly to the vehi-
cle.
(5) Install the seat hex nut at the heater mounting
flange to the cross members. Tighten to 60 Nm (44 ft.
lbs.)
(6) Install the heater exhaust tube flex section to
the exhaust tube by tightening the M6 bolt of the
clamp assembly. Install the hose to the exhaust tube.
(7) Tighten the two M8 fasteners at the rail to 23
Nm (17 ft. lbs.). Taking care so that the exhaust tube
bracket tab is on the top of the heater bracket.
(8) Install the wiring harness(Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
24a - 10 HEATING & AIR CONDITIONINGRG
FUEL LINE (Continued)

(9) Tighten the hose and tube assembly to the toe-
board cross member at two locations.
(10) Install the second hose to the underbody hose
and tube assembly.
(11) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(12) Remove the heater unit support device from
under the vehicle.
(13) Lower vehicle from lift.
(14) Refill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Verify function of the cabin heater.
SUPPLEMENTAL DIESEL
HEATER WIRING
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Unplug connector from vehicle wiring harness
to cabin heater harness.
(3) Unplug connector from cabin heater harness to
dosing pump connector.
(4) Unplug two connectors from cabin heater har-
ness to cabin heater controller connectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.
(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
AIR INTAKE PIPE
REMOVAL
NOTE: Heater air intake tube is part of an assembly
that includes the heater cooling intake and return
pipes. If heater air intake tube requires removal or
replacement the entire assembly will require remov-
al/replacement.
(1) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(2) Remove clamps from the heater tubes at the
lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the heater air
intake muffler connection(Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/INLET
MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 7).
(5) Remove the two retaining screws and remove
pipe assembly (Fig. 8).
Fig. 7 FLEXIBLE AIR INTAKE LINE
1 - HEATER UNIT AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
RGHEATING & AIR CONDITIONING24a-11
HEATER UNIT (Continued)

INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7 Nm
( 5 ft. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp.
(3) Install the flexible tube to the heater air intake
muffler and install and tighten the retaining clamp.
(4) Install the heater tubes to the lower heater
connection and the lower EGR cooler connection and
tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the cooling system(Refer to 7 - COOLING
- STANDARD PROCEDURE).
(7) Verify function of the heater unit.
Fig. 8 AIR INTAKE AND HEATER PIPE ASSEMBLY
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24a - 12 HEATING & AIR CONDITIONINGRG
AIR INTAKE PIPE (Continued)