Index CHRYSLER VOYAGER 1996 Owners Manual

PAINT
INDEX
page page
GENERAL INFORMATION
AFTERMARKET PAINT REPAIR PRODUCTS.... 3
BASE COAT/CLEAR COAT FINISH............ 2PAINT CODE............................ 2
PAINTED SURFACE TOUCH-UP............. 2
WET SANDING, BUFFING, AND POLISHING.... 2
GENERAL INFORMATION
PAINT CODE
A paint code is provided on the body code plate
located in the engine compartment. Refer to the
Introduction section at the front of this manual for
body code plate description. The paint and trim codes
are also included on the Vehicle Safety Label located
on the driver's door end frame.
BASE COAT/CLEAR COAT FINISH
On most vehicles a two-part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
WET SANDING, BUFFING, AND POLISHING
Minor acid etching, orange peel, or smudging in
clear coat or single-stage finishes can be reduced
with light wet sanding, hand buffing, and polishing.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly wet sanded (1500 grit) and pol-
ished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
23 - 2 BODYNS

STATIONARY GLASS
INDEX
page page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS................... 4
REMOVAL AND INSTALLATION
BODY SIDE/SLIDING DOOR STATIONARY
GLASS............................... 6REAR WINDOW.......................... 7
WINDSHIELD............................ 4
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
WINDSHIELD REMOVAL ± EXTERIOR METHOD
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Remove A-pillar trim panels.
(5) Disconnect wire connectors to windshield
defroster grid.
(6) Place protective covers over instrument panel
and hood.
(7) Remove windshield molding (Fig. 1). Using pli-
ers, pull outward on molding at the bottom of A-pil-
lars.
(8) Using a sharp cold knife, cut urethane adhe-
sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 2). A power
cutting device can be used if available.
(9) Remove windshield from vehicle.
23 - 4 BODYNS

SEATS
INDEX
page page
REMOVAL AND INSTALLATION
ARM REST.............................. 9
BENCH SEAT BACK COVER................ 9
BENCH SEAT BACK HINGE COVERS........ 10
BENCH SEAT BACK HINGE................. 9
BENCH SEAT RISER ± FIRST REAR......... 11
BENCH SEAT RISER ± SECOND REAR....... 11
BENCH SEAT TRACK ± SECOND REAR...... 11
BUCKET SEAT BACK ASSIST STRAP........ 12
BUCKET SEAT BACK..................... 12
BUCKET SEAT CUSHION PAN.............. 12
BUCKET SEAT CUSHION SIDE COVER....... 13
BUCKET SEAT RECLINER ± MANUAL........ 13
BUCKET SEAT RECLINER ± POWER......... 14
BUCKET SEAT RISER ± MANUAL TRACK..... 14
BUCKET SEAT TRACK FRONT COVER ±
POWER.............................. 15BUCKET SEAT TRACK REAR COVER ±
POWER.............................. 15
BUCKET SEAT TRACK ± MANUAL........... 14
BUCKET SEAT TRACK ± POWER........... 14
CHILD RESTRAINT SEAT MODULE.......... 16
HEAD RESTRAINT SLEEVE................ 18
HEAD RESTRAINT ± BENCH SEAT.......... 16
HEAD RESTRAINT ± BUCKET SEAT......... 17
HEATED SEAT HEATING ELEMENT.......... 18
HEATED SEAT MODULE.................. 18
HEATED SEAT SWITCH................... 19
MECHANICAL LUMBAR HANDLE ASSEMBLY . . 19
PLASTIC GROCERY BAG RETAINER......... 19
POWER SEAT SWITCH................... 20
RECLINER HANDLE ± MANUAL............. 20
UNDER SEAT STORAGE BIN GUIDE......... 21
UNDER SEAT STORAGE BIN LOCK/LATCH.... 21
UNDER SEAT STORAGE BIN............... 20
REMOVAL AND INSTALLATION
ARM REST
REMOVAL
(1) Using a screw driver, pry cap from side of arm
rest (Fig. 1).
(2) Remove bolt holding arm rest to seat back.
(3) Remove arm rest from seat.
INSTALLATION
(1) Place arm rest in position on seat.
(2) Install bolt to hold arm rest to seat back.
(3) Install cap into side of arm rest (Fig. 1).
BENCH SEAT BACK COVER
REMOVAL
(1) Remove plastic grocery bag retainer attaching
screws and remove retainer.
(2) Using a fork type prying tool (C4829), disen-
gage push-in fasteners holding bottom of seat back
cover to seat back frame (Fig. 2).
(3) Disengage hooks holding top of seat back cover
to seat back frame.
(4) Remove 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 push-in fasteners to hold bottom of seat
back cover to seat back frame (Fig. 2).
BENCH SEAT BACK HINGE
Bench seats equipped with child restraint seats
have an interlock feature that will not allow the seat
back to fold forward with the child seat open.
REMOVAL
(1) Remove bench seat back hinge covers.
(2) Remove shoulder bolts holding seat back hinge
to seat back frame (Fig. 3).
(3) Remove bolts holding seat back hinge to seat
cushion frame.
Fig. 1 Arm Rest
NSBODY 23 - 9

BODY COMPONENT SERVICE
INDEX
page page
DIAGNOSIS AND TESTING
WATER LEAKS.......................... 23
WIND NOISE........................... 24
SERVICE PROCEDURES
HEAT STAKING......................... 24
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM........ 25
A-PILLAR TRIM PANEL................... 25
COWL COVER.......................... 25
COWL TRIM............................ 25
FLOOR CARPET........................ 26
FRONT DOOR APPLIQUE................. 28
FRONT DOOR CHECK STRAP.............. 28
FRONT DOOR FRAME CLOSEOUT MOLDINGS . 29
FRONT DOOR GLASS RUN WEATHER-STRIP . . 30
FRONT DOOR GLASS.................... 29
FRONT DOOR HINGE.................... 30
FRONT DOOR INNER BELT MOLDING....... 31
FRONT DOOR LATCH STRIKER............ 32
FRONT DOOR LATCH.................... 31
FRONT DOOR LOCK CYLINDER............ 32
FRONT DOOR OUTER BELT MOLDING....... 33
FRONT DOOR OUTSIDE HANDLE........... 33
FRONT DOOR REFLECTOR............... 34
FRONT DOOR SILL PLATE................ 34
FRONT DOOR TRIM PANEL................ 34
FRONT DOOR WEATHER-STRIP............ 36
FRONT DOOR WINDOW CRANK............ 36
FRONT DOOR WINDOW REGULATOR....... 36
FRONT DOOR.......................... 27
FRONT SEAT........................... 37
FRONT WHEELHOUSE SPLASH SHIELD..... 37
FUEL FILL DOOR BLOCKER LATCH STRIKER . . 38
FUEL FILL DOOR BLOCKER LATCH......... 38
FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 38
FUEL FILLER HOUSING ± WITH BLOCKER
LATCH .............................. 39
GRILLE............................... 39
HEADLINING........................... 39
HOOD HINGE.......................... 41
HOOD LATCH STRIKER................... 42
HOOD LATCH.......................... 41
HOOD RELEASE CABLE.................. 42
HOOD RELEASE HANDLE................. 42
HOOD................................ 40
JACK STORAGE COVER.................. 43
LEFT D-PILLAR TRIM PANEL............... 43
LEFT QUARTER TRIM PANEL.............. 44
LIFTGATE CHMSL ACCESS PANEL.......... 47
LIFTGATE HINGE........................ 47LIFTGATE LATCH STRIKER................ 47
LIFTGATE LATCH........................ 47
LIFTGATE LOCK CYLINDER............... 48
LIFTGATE OUTSIDE HANDLE.............. 48
LIFTGATE PROP ASSEMBLY............... 49
LIFTGATE SILL PLATE.................... 49
LIFTGATE STABILIZER WEDGE STRIKER..... 49
LIFTGATE STABILIZER WEDGE............. 49
LIFTGATE TRIM PANEL................... 50
LIFTGATE UPPER FRAME MOLDING........ 50
LIFTGATE UPPER FRAME SIDE MOLDINGS . . . 51
LIFTGATE............................. 46
LOWER B-PILLAR TRIM COVER............ 51
LUGGAGE RACK CROSSBAR.............. 51
LUGGAGE RACK RISER COVER............ 52
LUGGAGE RACK SIDE RAIL............... 52
OVERHEAD GRAB-HANDLES.............. 52
QUARTER GLASS....................... 52
QUARTER TRIM BOLSTER................ 53
RADIATOR CLOSURE PANEL CROSSMEMBER . 53
RAIL LAMP MODULE..................... 54
REAR HEADER TRIM..................... 55
REAR HVAC LOUVER AND BEZEL.......... 55
RIGHT D-PILLAR TRIM PANEL.............. 55
RIGHT QUARTER TRIM PANEL............. 56
ROOF APERTURE (RAP) MOLDING.......... 57
SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET............................. 58
SEAT BELT BUCKLE FIRST REAR ± TWO
PASSENGER BENCH................... 58
SEAT BELT BUCKLE SECOND REAR ± THREE
PASSENGER BENCH................... 59
SEAT BELT BUCKLE ± FRONT INBOARD..... 57
SEAT BELT FIRST REAR ANCHOR BRACKET ±
LWB ................................ 59
SEAT BELT FIRST REAR OUTBOARD ± LWB
FOUR DOOR.......................... 60
SEAT BELT FIRST REAR OUTBOARD ± SWB
FOUR DOOR.......................... 60
SEAT BELT LEFT FIRST REAR OUTBOARD ±
LWB THREE DOOR..................... 61
SEAT BELT LEFT FIRST REAR OUTBOARD ±
SWB THREE DOOR.................... 61
SEAT BELT SECOND REAR OUTBOARD ±
SWB ................................ 61
SEAT BELT SECOND RIGHT REAR OUTBOARD
±LWB ............................... 62
SEAT BELT ± OUTBOARD FRONT........... 59
SECOND RIGHT REAR OUTBOARD SEAT BELT
± LWB W/REAR HVAC................... 62
23 - 22 BODYNS

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

BODY COMPONENT SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE.................... 3LIFTGATE CHMSL ACCESS PANEL........... 3
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE
REMOVAL
(1) Lift the parking brake lever to the full up posi-
tion (Fig. 1).
(2) Carefully pull the base of the gearshift boot off
the top of the gearshift console.
(3) Remove the four (4) screws from the top of the
gearshift console (Fig. 2).
(4) Tilt the gearshift boot and carefully push the
boot through the opening in the gearshift console.
(5) Separate console from vehicle.
INSTALLATION
(1) Tilt the gearshift boot and carefully push the
boot through the gearshift console.
(2) Install screws to hold gearshift console to gear-
shift mechanism.
(3) Install gearshift boot and carefully push the
clips into the three (3) slots in the gearshift console.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clip
holding CHMSL access panel to liftgate trim panel
(Fig. 3).
(2) Disengage hooks on CHMSL access cover from
liftgate trim panel.
(3) Separate access panel from vehicle.
Fig. 1 Console, Parking Brake Lever, and Gearshift
Boot
Fig. 2 Gearshift Console and Boot Removal
NS/GSBODY 23 - 3

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

REAR HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 41
DESCRIPTION AND OPERATION
REAR BLOWER RESISTOR BLOCK.......... 41
REAR HEATER AND A/C LINES............. 41
SYSTEM OPERATION.................... 41
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES............... 43
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT-A/C.............. 43
AIR DISTRIBUTION DUCT-HEATER.......... 43
EVAPORATOR AND EXPANSION VALVE...... 44MODE DOOR ACTUATOR................. 49
MODE DOOR........................... 49
REAR AIR CONDITIONING LINES........... 45
REAR HEATER A/C AIR OUTLETS........... 45
REAR HEATER A/C BLOWER MOTOR........ 46
REAR HEATER A/C UNIT.................. 46
REAR HEATER CORE.................... 48
REAR HEATER LINES.................... 49
REAR HEATER-A/C AUXILIARY CONDENSER . . 45
REAR HEATER-A/C CONTROL ILLUMINATION
BULB............................... 46
GENERAL INFORMATION
INTRODUCTION
For proper operation of the rear heating A/C sys-
tem, refer to Owner's Manual supplied with the vehi-
cle.
DESCRIPTION AND OPERATION
REAR BLOWER RESISTOR BLOCK
The rear blower motor resistor is not serviceable
separately. The resistor is integral to the blower
motor. If resistor is faulty, it is necessary to replace
the complete blower motor.
REAR HEATER AND A/C LINES
The rear heater and A/C lines are all serviced as
individual pieces. When disconnecting any line orblock ensure that the area around it is clean of any
contaminations that can get in to the system (Fig. 1),
(Fig. 2), (Fig. 4), (Fig. 3) and (Fig. 5).
SYSTEM OPERATION
The auxiliary rear heating-air/conditioning unit is
located in the right rear quarter panel. The rear
heater A/C control operates in conjunction with the
front heater A/C control. A four position two speed
blower (override) switch is located on the front
Heater A/C control panel (Fig. 6). The operator can
use the rear heater A/C blower switch to operate the
blower, regardless of the rear control setting. In the
OFF position, the rear control will not function. In
the ON (RR) position, the rear control will function
normally providing three speeds (Fig. 7). The mode
setting is controlled by the front A/C control panel.
Fig. 1 Rear Heater and A/C Lines
NSHEATING AND AIR CONDITIONING 24 - 41

EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS........ 13
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM.............................. 18ON-BOARD DIAGNOSTICS.................. 1
ON-BOARD DIAGNOSTICS
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION................... 1
DESCRIPTION AND OPERATION
CIRCUIT ACTUATION TEST MODE........... 3
COMPONENT MONITORS................. 10
DIAGNOSTIC TROUBLE CODES............. 3
HIGH AND LOW LIMITS................... 11LOAD VALUE........................... 12
MALFUNCTION INDICATOR LAMP (MIL)....... 1
MONITORED SYSTEMS.................... 8
NON-MONITORED CIRCUITS............... 11
STATE DISPLAY TEST MODE............... 2
TRIP DEFINITION........................ 10
GENERAL INFORMATION
SYSTEM DESCRIPTION
The Powertrain Control Module (PCM) monitors
many different circuits in the fuel injection, ignition,
emission and engine systems. If the PCM senses a
problem with a monitored circuit often enough to
indicate an actual problem, it stores a Diagnostic
Trouble Code (DTC) in the PCM's memory. If the
code applies to a non-emissions related component or
system, and the problem is repaired or ceases to
exist, the PCM cancels the code after 40 warmup
cycles. Diagnostic trouble codes that affect vehicle
emissions illuminate the Malfunction Indicator Lamp
(MIL). Refer to Malfunction Indicator Lamp in this
section.
Certain criteria must be met before the PCM
stores a DTC in memory. The criteria may be a spe-
cific range of engine RPM, engine temperature,
and/or input voltage to the PCM.
The PCM might not store a DTC for a monitored
circuit even though a malfunction has occurred. This
may happen because one of the DTC criteria for the
circuit has not been met.For example, assume the
diagnostic trouble code criteria requires the PCM to
monitor the circuit only when the engine operates
between 750 and 2000 RPM. Suppose the sensor'soutput circuit shorts to ground when engine operates
above 2400 RPM (resulting in 0 volt input to the
PCM). Because the condition happens at an engine
speed above the maximum threshold (2000 rpm), the
PCM will not store a DTC.
There are several operating conditions for which
the PCM monitors and sets DTC's. Refer to Moni-
tored Systems, Components, and Non-Monitored Cir-
cuits in this section.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, use the DRB scan tool to
erase all DTC's and extinguish the MIL.
Technicians can display stored DTC's by using the
DRB scan tool. Refer to Diagnostic Trouble Codes in
this section. For DTC information, refer to charts in
this section.
DESCRIPTION AND OPERATION
MALFUNCTION INDICATOR LAMP (MIL)
As a functional test, the Malfunction Indicator
Lamp (MIL) illuminates at key-on before engine
NSEMISSION CONTROL SYSTEMS 25 - 1

EVAPORATIVE EMISSION CONTROLS
INDEX
page page
DESCRIPTION AND OPERATION
CRANKCASE VENT FILTER................ 16
EVAPORATION CONTROL SYSTEM......... 13
EVAPORATIVE (EVAP) CANISTER........... 13
LEAK DETECTION PUMP................. 14
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEMS............................ 15
PRESSURE-VACUUM FILLER CAP.......... 14
PROPORTIONAL PURGE SOLENOID......... 13ROLLOVER VALVE....................... 13
VEHICLE EMISSION CONTROL INFORMATION
LABEL............................... 16
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP................. 16
PCV VALVE TEST....................... 16
REMOVAL AND INSTALLATION
LEAK DETECTION PUMP REPLACEMENT.... 16
ROLLOVER VALVES..................... 17
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
The evaporation control system prevents the emis-
sion of fuel tank vapors into the atmosphere. When
fuel evaporates in the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal filled evap-
orative canister. The canister temporarily holds the
vapors. The Powertrain Control Module (PCM) allows
intake manifold vacuum to draw vapors into the com-
bustion chambers during certain operating condi-
tions.
All engines use a duty cycle purge system. The
PCM controls vapor flow by operating the duty cycle
EVAP purge solenoid. Refer to Duty Cycle EVAP
Purge Solenoid in this section.
NOTE: The evaporative system uses specially man-
ufactured hoses. If they need replacement, only use
fuel resistant hose.
ROLLOVER VALVE
All vehicles have a rollover valve. The valve also
prevents fuel flow through the fuel tank vent valve
hoses should the vehicle rollover. All vehicles pass a
360É rollover.
The charcoal filled evaporative canister stores the
vapors. The rollover valve is not a serviceable item.
EVAPORATIVE (EVAP) CANISTER
All vehicles use a sealed, maintenance free, evapo-
rative (charcoal) canister. The canister is attached to
the frame under the driver's seat (Fig. 1).
Fuel tank vapor vents into the canister. The canis-
ter temporarily holds the fuel vapors until intake
manifold vacuum draws them into the combustion
chamber. The canister proportional purge solenoidallows the canister to be purged at predetermined
intervals and engine conditions.
PROPORTIONAL PURGE SOLENOID
All vehicles use a Proportional purge solenoid. The
solenoid regulates the rate of vapor flow from the
EVAP canister to the throttle body. The PCM oper-
ates the solenoid.
During the cold start warm-up period and the hot
start time delay, the PCM does not energize the sole-
noid. When de-energized, no vapors are purged. The
PCM de-energizes the solenoid during open loop oper-
ation.
Fig. 1 Evaporative Canister
NSEMISSION CONTROL SYSTEMS 25 - 13