engine coolant CHRYSLER VOYAGER 1996 Service Manual

(2) Remove the sensor mounting bolts.
(3) Remove the sensor.
INSTALLATION
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the sensor mounting bolt to
19 N´m (14 ft. lbs.) torque.
(3) Connect the electrical connector to the sensor.
ENGINE COOLANT TEMPERATURE SENSOR
The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 19).
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Partially drain cooling system. Refer to Group
7, Cooling.
(2) Disconnect electrical connector from sensor.
(3) Remove sensor from cylinder head.
INSTALLATION
(1) Install a new copper gasket to sensor.
(2) Install sensor to cylinder head.
(3) Tighten sensor to 18 N´m (13 ft. lbs.) torque.
(4) Connect electrical connector to sensor.
(5) Replace any lost engine coolant. Refer to Group
7, Cooling System.
GLOW PLUGS
The glow plugs are located above each fuel injector
(Fig. 20). Four individual plugs are used.
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Clean the area around the glow plug with com-
pressed air before removal.
(3) Disconnect electrical connector (Fig. 21) at glow
plug.
(4) Remove the glow plug (Fig. 20) from cylinder
head.
Fig. 18 Engine Speed SensorFig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Glow Plug
14 - 54 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

OPERATION
The gear ratios for the 41TE transaxle are as fol-
lows:
²1stÐ2.84
²2ndÐ1.57
²3rdÐ1.00
²ODÐ0.69
²ReverseÐ2.21
Final Drive Ratio is dependent on which engine
option is selected.
²2.4 Liter: 3.91 FDR
²3.3 Liter: 3.62 FDR
²3.8 Liter: 3.45 FDR
The torque converter clutch is available in 2nd,
direct, or overdrive gear;. The shift lever is conven-
tional with six positions: P, R, N, OD, 3, and L avail-
able. When OD is selected the transaxle shifts
through all four speeds with torque converter clutch
available in overdrive. This position is recommended
for most driving. The 3 position is tailored for use in
hilly or mountainous driving. When 3 is selected, the
transmission uses only 1st, 2nd, and direct gears
with 2nd-direct shift delayed to 40 mph or greater.
When operating in 3 or L positions torque converter
clutch application occurs in direct gear. This
improves transmission cooling under heavy loads. If
high engine coolant temperature occurs, the torque
converter clutch will also engage in 2nd gear. The L
position provides maximum engine braking for
descending steep grades. Unlike most current tran-
saxles, upshifts are provided to 2nd or direct gear at
peak engine speeds if the accelerator is depressed.
This provides engine over-speed protection and max-
imum performance.
FLUID LEVEL AND CONDITION
NOTE: The transmission and differential sump have
a common oil sump with an opening between the
two.
The torque converter fills in both the (P) Park and
(N) Neutral positions. Place the selector lever in (P)
Park to check the fluid level.The engine should be
running at idle speed for at least one minute,
with the vehicle on level ground. This will
assure complete oil level stabilization between
differential and transmission.The fluid should be
at normal operating temperature (approximately 82
C. or 180 F.). The fluid level is correct if it is in the
HOTregion (cross-hatched area) on the oil level indi-
cator.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in
the 41TE transaxle. MOPARtATF PLUS 3 (Auto-
matic Transmission FluidÐtype 7176) should be used
to aid in assuring optimum transmission perfor-
mance. Fluids of the type labeled DEXRON II Auto-
matic Transmission Fluid arenot recommended.It
is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the
addition of any fluids to the transaxle, other than the
fluid listed above. An exception to this policy is the
use of special dyes to aid in detecting fluid leaks. The
use of transmission sealers should be avoided, since
they may adversely affect seals.
DESCRIPTION AND OPERATION
CLUTCH AND GEAR
The transaxle consists of:
²Three multiple disc input clutches
²Two multiple disc grounded clutches
²Four hydraulic accumulators
²Two planetary gear sets
This provides four forward ratios and a reverse
ratio. The input clutch-apply pistons were designed
with centrifugally balanced oil cavities so that quick
response and good control can be achieved at any
speed. A push/pull piston is incorporated for two of
the three input clutches.
21 - 72 TRANSAXLE AND POWER TRANSFER UNITNS
GENERAL INFORMATION (Continued)

INSTALLATION
To install valve body, reverse removal procedure
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
NOTE: To ease installation of the valve body, turn
the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while
shifting manual lever assembly out of the installation
position.
TRANSAXLE
Transaxle removal does NOT require engine
removal.
See Group 7, Cooling to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only).The transaxle and torque converter must be
removed as an assembly; otherwise, the torque con-
verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner duct. Disconnect transaxle
shift linkage at manual valve lever (Fig. 34).
(3) Squeeze grommet clips and remove cable at
transaxle bracket (Fig. 35) (Fig. 36).
(4) Remove 16±way engine harness connector from
dipstick tube bracket. Remove dipstick tube bracket
nut at cylinder head. Remove dipstick tube.
(5) Remove transaxle cooler lines.
(6) Remove connector at transaxle solenoid pack.
(7) Remove input and output speed sensor wiring
connectors (Fig. 37) (Fig. 38).
Fig. 32 Remove Valve Body
Fig. 33 Valve Body Removed
Fig. 34 Shift Linkage At Manual Valve Lever
Fig. 35 Grommet Clips
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 89
REMOVAL AND INSTALLATION (Continued)

DIFFERENTIAL BEARING RETAINER AXLE
SEAL
REMOVAL
(1) Remove axle shaft. Refer to Group 2, Suspen-
sion and Driveshafts for service procedures.
(2) Insert a flat±blade pry tool into the axle seal
bore.
(3) Using the pry tool, carefully pop out the seal
taking care not to nick the seal bore.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Position axle seal at extension housing.
(4) Using Tool L-4520 and Tool C-4171, tap seal
into position.
SHIFT SHAFT SEALS
It isnotnecessary to remove the shift shaft cover
from the transaxle to service the shift shaft seals.
REMOVAL
(1) Remove the shift lever from the seal that is to
be serviced. Refer to shift lever removal for service
procedure.
(2) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep±well socket.
TRANSAXLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
²Gearshift housing
²5th speed synchronizer
²5th speed gear
²Roller detents and springs
²Speedometer pinion
²Vehicle speed sensor
²Bearing retainer plate.
²All external covers
²Shift shaft seals
²Axle shaft seals
To service any other component of the A-598 tran-
saxle you must remove it from the vehicle.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air intake hose. Disconnect air mass
meter connector.
(3) Remove intercooler hose.(4) Remove connectors for back-up lamp (Fig. 28)
and crank position sensor (Fig. 29).
(5) Remove crank position sensor (2.5L VM Diesel
only).
(6) Remove wiring harness bracket at transaxle
(Fig. 30).
(7) Remove crossover and shift selector cables (Fig.
31).
(8) Remove the two top bolts at the rear engine
mount bracket.
(9) Remove bolts securing the coolant reservoir to
the top of the engine. Move the coolant reservoir out
of the way.
(10) Install an engine support chain to the cylinder
head assembly (Fig. 32).
Fig. 28 Back-up Lamp Connector
Fig. 29 Crankshaft Position Sensor
21 - 12 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)

(5) Remove nuts holding quarter glass to C-pillar
(Fig. 72).
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts to attach quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw holding quarter window retainer
to vent motor arm.
(5) Close quarter glass.
(6) Install C-pillar trim.
QUARTER TRIM BOLSTER
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
REMOVAL
(1) Disengage hidden clips holding trim bolster to
quarter trim panel (Fig. 73) and (Fig. 74).
(2) Disengage hook retainer holding front of trim
bolster to quarter trim panel, if applicable (Fig. 73).
(3) Remove quarter trim bolster from vehicle.
INSTALLATION
(1) Place quarter trim bolster in position on vehi-
cle.
(2) Engage hook retainer to hold front of trim bol-
ster to quarter trim panel, if applicable.
(3) Engage hidden clips to hold trim bolster to
quarter trim panel.
RADIATOR CLOSURE PANEL CROSSMEMBER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove bolt holding air cleaner housing to
crossmember.
(6) Remove screw holding coolant recovery bottle
to crossmember.
(7) Remove bolts holding radiator isolators to
crossmember.
(8) Remove bolts holding ends of crossmember to
radiator closure panel (Fig. 75).
(9) Lift crossmember upward and away from radi-
ator closure panel.
(10) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.
Fig. 72 Quarter Glass
Fig. 73 Left Quarter Trim Bolster ± LWB Four Door
Fig. 74 Left Quarter Trim Bolster ± SWB and LWB
Three Door
NSBODY 23 - 53
REMOVAL AND INSTALLATION (Continued)

(3) Install bolts to hold ends of crossmember to
radiator closure panel (Fig. 75).
(4) Install bolts to hold radiator isolators to cross-
member.
(5) Install screw to hold coolant recovery bottle to
crossmember.
(6) Install bolt to hold air cleaner housing to cross-
member.
(7) Install engine air inlet resonator.
(8) Install radiator sight shield.
(9) Align hood latch by placing latch over netpierce
tabs. If alignment is required, flatten tabs.
(10) Install bolts to hold hood latch to crossmem-
ber.
(11) Verify hood latch operation and hood align-
ment.
RAIL LAMP MODULE
WITHOUT REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail.
(3) Remove rail lamp module from headlining (Fig.
76).
(4) Disconnect wire connector from body wiring
harness.
(5) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module in vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screw attaching module to roof rail
inside coat hook.
WITH REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail inside coat hook (Fig. 77).
(3) Remove screws attaching rail lamp module to
roof rail from behind grab handle.
(4) Remove rail lamp module from headlining.
(5) Disconnect wire connector from body wiring
harness.
(6) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module to vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screws to attach rail lamp module to
roof rail behind grab handle.
(5) Install screw to attach rail lamp module to roof
rail inside coat hook.
Fig. 75 Radiator Closure Panel CrossmemberFig. 76 Rail Lamp Module ± w/o Rear HVAC
Fig. 77 Rail Lamp Module ± w/Rear HVAC
23 - 54 BODYNS
REMOVAL AND INSTALLATION (Continued)

GENERAL INFORMATION
INTRODUCTION
Both the heater and the heater/air conditioning
systems share many of the same components. This
group will deal with both systems together when
component function is common, and separately when
they are not.
For proper operation of the instrument panel con-
trols, refer to the Owner's Manual provided with the
vehicle.
All vehicles are equipped with a common A/C-
heater unit housing assembly. When the vehicle has
only a heater system, the evaporator and recirculat-
ing air door are omitted.
An optional zone control HVAC unit is available.
This unit has dual blend-air doors that can be regu-
lated independently of each other. The temperature
setting can be different from driver's side to passen-
ger side. There is also a rear (aux.) heating and A/C
system available when the vehicle is equipped with
zone control.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED ORINHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
SONAL INJURY CAN RESULT.
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
DESCRIPTION AND OPERATION
AIR DISTRIBUTION DUCTS
The air distribution ducts for the A/C, Heater,
Defroster, and Second Seating Air Distribution are
not serviceable in vehicle. The procedures for service
of these ducts are covered in Group 8E, Instrument
Panel and Gauges.
The only ducts that are serviceable in the vehicle
are the side window demister ducts and the ducts
that feed the front door outlets for the first rear pas-
senger(s) seating. To service the door ducts refer to
Group 23, Body.
A/C PRESSURE TRANSDUCER
The A/C Pressure Transducer (Fig. 1) monitors the
refrigerant gas pressure on the high side of the sys-
tem. The transducer is located on the liquid line. The
pressure transducer turns off the voltage to the com-
pressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor.
The transducer also is used to adjust condenser fan
speeds and will turn off compressor at high refriger-
ant pressures. The pressure transducer is a sealed
factory calibrated unit. It must be replaced if defec-
tive. O-ring replacement is required whenever the
pressure transducer is serviced. Be sure to use the
O-ring specified for the transducer.
A/C SERVICE PORTS
The A/C service port valve cores are located within
the A/C lines (Fig. 2). The High Side (Discharge)
valve service port is located on the liquid line near
the right frame rail. The Low Side (Suction) valve
service port is located on the suction line near the
compressor.
24 - 2 HEATING AND AIR CONDITIONINGNS

CAUTION: The refrigerant oil used in a R-134a A/C
system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil
designated for this vehicle is ND8 PAG (polyalka-
lene glycol).
SERVICING REFRIGERANT OIL LEVEL
(1) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(2) Remove refrigerant lines from A/C compressor.
(3) Remove compressor from vehicle.
(4) From suction port on top of compressor, drain
refrigerant oil from compressor.
(5) Add system capacity minus the capacity of
components that have not been replaced through suc-
tion port on compressor. Refer to the Refrigerant Oil
Capacity Chart.
(6) Install compressor, connect refrigerant lines,
evacuate, and charge refrigerant system.
DIAGNOSIS AND TESTING
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST
GENERAL INFORMATION
If the HVAC control module is replaced, the Cali-
bration Diagnostic and Cooldown tests will need to
be performed. Once this group of tests have success-
fully passed, they can be performed individually. The
engine must be running during the test to provide
hot coolant for the heater, A/C compressor operation
and to assure that the actuators are calibrated cor-
rectly. The HVAC control module is capable of trou-
bleshooting the system in approximately 120 seconds.
If a condition is detected, an error code is displayed.
The error code cannot be erased until the condition is
repaired and the diagnostic test is performed. Check
wire before replacing components, refer to Group 8W,
Wiring Diagrams.CAUTION: Do not remove the actuators from the
Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF.
The actuators have no mechanical stops to limit the
travel. If the actuator rotates and is not connected
to the unit assembly, it will become out of calibra-
tion.
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibra-
tion compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In-
vehicle calibration can be entered from the control's
front panel. If the REAR WIPE and INTERMIT-
TENT LED's flash simultaneously when Ignition is
cycled ON, the actuators have not been calibrated or
during the previous calibration a failure occurred
(Fig. 6) and (Fig. 7). Diagnostics will always occur
during Calibration Diagnostic and Cooldown test.
REFRIGERANT OIL CAPACITIES
Refrigerant
Oil Capaci-
tiesFront A/C Dual A/C
Component ml oz ml oz
Compressor 150 ml 5.0 oz 220 ml 7.4 oz
Filter-Drier 30 ml 1.0 oz 30 ml 1.0 oz
Condenser 30 ml 1.0 oz 30 ml 1.0 oz
Evaporator 60 ml 2.0 oz 60 ml 2 .0 oz
Rear Evap. N/A N/A 60 ml 2.0 oz
Fig. 6 Radio Bezel and HVAC Control
24 - 6 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)

be 21ÉC to 27ÉC (70ÉF to 85ÉF). To test the expansion
valve:
NOTE: Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set heater A/C control to A/C, full heat,
FLOOR, and high blower.
(4) Start the engine and allow to idle (1000 rpm).
After the engine has reached running temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the evaporator.
(5) If the refrigerant charge is sufficient, discharge
(high pressure) gauge should read 965 to 1655 kPa
(140 to 240 psi). Suction (low pressure) gauge should
read 140 kPa to 207 kPa (20 psi to 30 psig). If system
cannot achieve proper pressure readings, replace the
expansion valve. If pressure is correct, proceed with
test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(6) If suction side low pressure is within specified
range, freeze the expansion valve control head for 30
seconds. Use a super cold substance (liquid CO2).Do
not spray R-134a or R-12 Refrigerant on the
expansion valve for this test.Suction side low
pressure should drop by 10 psi. If not, replace expan-
sion valve.
(7) Allow expansion valve to thaw. The low pres-
sure gauge reading should stabilize at 140 kPa to
240 kPa (20 psi to 30 psig). If not, replace expansion
valve.
(8) When expansion valve test is complete, test
A/C overall performance. Remove all test equipment
before returning vehicle to use.
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
Review Safety Precautions and Warnings in this
group before performing the following procedures.
Check the coolant level, drive belt tension, vacuum
line connections, radiator air flow and fan operation.
Start engine and allow to warm up to normal tem-
perature.WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing cap. Place a rag over the cap and
turn it to the first safety stop. Allow pressure to
escape through the overflow tube. When the system
stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With engine idling at normal running temperature,
set the control to maximum heat, floor, and high
blower setting. Using a test thermometer, check the
air temperature coming from the floor outlets, refer
to Temperature Reference Table.
If the floor outlet air temperature is insufficient,
refer to Group 7, Cooling Systems for specifications.
Both heater hoses should be HOT to the touch (cool-
ant return hose should be slightly cooler than the
supply hose). If coolant return hose is much cooler
than the supply hose, locate and repair engine cool-
ant flow obstruction in heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pinched or kinked heater hoses.
(2) Improper heater hose routing.
(3) Plugged heater hoses or supply and return
ports at cooling system connections, refer to Group 7,
Cooling System.
(4) Plugged heater core.
(5) Air locked heater core.
(6) If coolant flow is verified and outlet tempera-
ture is insufficient, a mechanical problem may exist.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl air intake.
(2) Obstructed heater system outlets.
(3) Blend-air door not functioning properly.
TEMPERATURE REFERENCE TABLE
AMBIENT
TEMPERATUREMINIMUM FLOOR
OUTLET TEMPERATURE
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
NSHEATING AND AIR CONDITIONING 24 - 15
DIAGNOSIS AND TESTING (Continued)

TEMPERATURE CONTROL
If temperature cannot be adjusted with the TEMP
lever on the control panel, the following could require
service:
(1) Blend-air door binding.
(2) Faulty blend-air door motor.
(3) Improper engine coolant temperature.
(4) Faulty Instrument Panel Control.
SYSTEM CHARGE LEVEL TEST
The procedure below should be used to check
and/or fill the refrigerant charge in the air condition-
ing system.
NOTE: The amount of R134a refrigerant that the air
conditioning system holds is:
²Without rear A/C± .96 kg (34 oz. or 2.13 lbs.)
²With Rear A/C± 1.36 kg (48 oz. or 3.00 lbs.)
NOTE: Low Charge, condition may be described
as:
²Loss of A/C performance
²Fog from A/C outlets
²evaporator may have a HISS sound
There are two different ways the system can be
tested:
²With a scan tool (DRB), thermocouple and the
Charge Determination Graph. Use the scan tool
(DRB) diagnostic topic: Engine±System Monitors, A/C
Pressure.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Graph.
It is recommended to use the gauges or reclaim/re-
cycle equipment.
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME
MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO
BE COMBUSTIBLE AT ELEVATED PRESSURES.
THESE MIXTURES ARE POTENTIALLY DANGER-
OUS AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
(1) Establish your preferred method of measuring
liquid line pressure. Use a manifold gauge set or a
DRB scan tool.(2) Attach a clamp-on thermocouple (P.S.E. 66-324-
0014 or 80PK-1A) or equivalent to the liquid line. It
must be placed as close to the A/C Pressure Trans-
ducer as possible to observe liquid line temperature.
Refer to ªThermocouple Probeº in this section for
more information on probe.
(3) The vehicle must be in the following modes:
²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set to Outside Air
²Panel Mode
²Full Cool
²High Blower motor, (vehicle equipped with rear
A/C turn rear blower motor ON HIGH)
²A/C Button in the ON position
²Vehicle Windows Open.
²Recirc. button turned OFF
(4) Operate system for a couple of minutes to allow
the system to stabilize.
(5) Set system pressure to about 1793 kPa (260
psi) by placing a piece of cardboard over part of the
front side of the condenser. To place cardboard prop-
erly, remove the upper radiator-condenser cover.
Insert cardboard between condenser and radiator
front. This will maintain a constant pressure.
(6) Observe Liquid Line pressure and Liquid line
temperature. Using theCharge Determination
Chartdetermine where the system is currently oper-
ating. If the system is in the undercharged region,
ADD 0.057 Kg. (2 oz.) to the system and recheck
readings. If the system is in the overcharged region,
RECLAIM 0.057 Kg. (2 oz.) from the system and
recheck readings. Continue this process until the sys-
tem readings are in the proper charge area on the
Charge Determination Chart.
(7) The same procedure can be performed using
the scan tool (DRB). To determine liquid line pres-
sure, attach the scan tool, go to System Moni-
tors±A/C Pressure. Observe liquid line pressure from
A/C Pressure Transducer on digital display and digi-
tal thermometer. Refer toCharge Determination
Chartand determine where the system is operating.
SERVICE PROCEDURES
R-134a REFRIGERANT
This vehicle uses a new type of refrigerant called
R-134a. It is a non-toxic, non-flammable, clear color-
less liquefied gas.
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause
compressor failure, refrigerant oil to sludge and/or
poor performance.Never add any other type of
refrigerant to a system designed to use R-134a
refrigerant. System failure will occur.
24 - 16 HEATING AND AIR CONDITIONINGNS
DIAGNOSIS AND TESTING (Continued)