heater CHRYSLER VOYAGER 1996 Service Manual

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)

(2) Remove liquid line at filter-drier (Fig. 42).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
Torque filter/drier mounting bolts to 45 in. lbs.610.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system (Fig. 43).
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Pinch off rear heater lines if equipped.
(6) Drain engine coolant. Remove heater hoses at
the heater core (Fig. 44). Plug coolant lines.
(7) Remove suction and liquid lines at the expan-
sion valve (Fig. 45).(8) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Gauges.
(9) Remove heater ducts.
Fig. 42 Filter-Drier Assembly
Fig. 43 A/C Service Ports
Fig. 44 Heater Hoses
Fig. 45 Expansion Valve Plate
NSHEATING AND AIR CONDITIONING 24 - 29
REMOVAL AND INSTALLATION (Continued)

(10) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(11) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 46).
(12) Disconnect the HVAC housing wiring harness.
(13) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
47).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 48).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 49)
(7) Pinch off heater lines under the hood.
(8) Remove heater core cover. Insert a small
amount of towels under the heater core tubes.
Remove heater core plate and tubes (Fig. 50).
(9) Depress heater core retaining clips (Fig. 51).
(10) Pull up on accelerator pedal and slide heater
core past (Fig. 52).(11) Depress brake pedal (Fig. 53) and remove
heater core from HVAC housing.
Fig. 46 HVAC Bolt-Up
Fig. 47 ABS MODULE
Fig. 48 Interconnect And Bracket
Fig. 49 Lower Silencer Boot
24 - 30 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
For installation, reverse the above procedures.
Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tightenheater core tube retaining plate to 361 N´m (276
9 in. lbs.) torque.
HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Drain engine cooling system. Refer to Group 7,
Engine Cooling.
(2) Loosen clamps at each end of heater hose to be
removed (Fig. 54) and (Fig. 55).
Fig. 50 Heater Core Plate And Tubes
Fig. 51 Depress Clips
Fig. 52 Accelerator Pedal
Fig. 53 Brake Pedal
Fig. 54 Upper Heater Hose
NSHEATING AND AIR CONDITIONING 24 - 31
REMOVAL AND INSTALLATION (Continued)

CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant.
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple. If the hose
will not come off, slice the hose at the connector nip-
ple and peel off heater hose. This method will require
heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
LIQUID LINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Recover A/C system refrigerant.
(3) Remove the accessory drive belt.
(4) Remove upper generator bracket.
(5) Remove ground wire at dash panel.
(6) Remove the nut retaining the refrigerant line
sealing plate to the expansion valve (Fig. 39).
(7) Remove the stud from the expansion valve (Fig.
40).
(8) Remove liquid line from expansion valve.
(9) Cover the openings to prevent contamination.
(10) Disconnect wire connector at pressure trans-
ducer.
(11) Remove liquid line mounting bracket at right
frame rail.
(12) Using access slot between radiator crossmem-
ber and grille, loosen liquid line mounting plate at
filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to
remove line. The replacement line is a two-piece
assembly.
(13) Remove the old O-rings.
INSTALLATION
For installation, reverse the above procedures.
²Install the stud to the evaporator sealing plate
and tighten 7 to 11 N´m (64 to 96 in. lbs.) torque.
²Install new O-rings.
²Install two-piece line in place of original part.
²A
ssemble line halves after it is installed on vehicle.²Evacuate and recharge A/C system.
MODE DOOR ACTUATOR
REMOVAL
(1) Remove the lower left side steering column
cover. Refer to Group 8E, Instrument Panel and Sys-
tems.
(2) Remove ABS control module (Fig. 56).
(3) Remove mode actuator connector (Fig. 57).
(4) Remove mode door actuator (Fig. 58).
INSTALLATION
(1) For installation, reverse the above procedures.
Fig. 55 Lower Heater Hose
Fig. 56 ABS Control Module
Fig. 57 Mode Door Actuator Connector
24 - 32 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

²Install two-piece line in place of original part.
²Assemble line halves after it is installed on vehi-
cle.
²Evacuate and recharge A/C system.
RECIRC DOOR ACTUATOR
REMOVAL
(1) Pull back on carpeting on the right lower floor.
(2) Remove Recirc. door actuator connector.
(3) Remove (3) mounting screws for Recirc. actua-
tor (Fig. 62).
(4) Remove Recirc. actuator.
(5) Disengage actuator linkage at Recirc. door.
(6) Remove actuator from vehicle.
INSTALLATION
(1) For installation, reverse the above procedures.
(2) Perform the HVAC control Calibration Diagnos-
tic and Cooldown test.
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION
Heater A/C Housing must be removed from vehicle
before performing this operation. Refer to Heater A/C
Unit HousingÐRemoval and Installation.
DISASSEMBLYÐEVAPORATOR HOUSING
(1) Place HVAC unit assembly on workbench.
(2) Remove distribution housing mounting screws
(Fig. 63).
(3) Remove blower motor cover (Fig. 64).
(4) Remove blower motor wiring grommet and feed
wiring through blower housing (Fig. 65).
(5) Remove blower motor screws. Remove blower
motor from housing (Fig. 66) and (Fig. 67).
(6) Remove recirculation door cover (Fig. 68).(7) Remove Recirc. door (Fig. 69).
(8) Remove screws around the perimeter of the
upper HVAC housing (Fig. 70).
Fig. 62 Recirculation Door Actuator
Fig. 63 Distribution Housing
Fig. 64 Blower Motor Cover
Fig. 65 Blower Motor Grommet
24 - 34 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: Do not damage the insulation barrier
surrounding the evaporator.(9) Carefully pull up on evaporator and remove
from housing (Fig. 71).
(10) If replacing evaporator, drain and measure
amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new evaporator
before installing. Use SP 10 PAG oil for 2.5L diesel
and 2.0L gasoline engine vehicles.
ASSEMBLYÐEVAPORATOR HOUSING
(1) For reassembly of the evaporator housing,
reverse the above procedures.
(2) Perform the HVAC control Calibration Diagnos-
tic and Cooldown test.
DISASSEMBLYÐDISTRIBUTION HOUSING
(1) Place distribution housing on workbench (Fig.
72).
(2) Remove heater core cover (Fig. 73).
(3) Remove heater core tube plate (Fig. 74) and
(Fig. 75).
(4) Remove heater core tubes (Fig. 76).
Fig. 66 Blower Motor Screws
Fig. 67 Blower Motor
Fig. 68 Recirculation Door Cover
Fig. 69 Recirc. Door
Fig. 70 HVAC Cover
NSHEATING AND AIR CONDITIONING 24 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

(5) Depress heater core retaining clips at housing.
When reinstalling core use screws to fasten the
heater core to the housing.
(6) Slide heater core out of the housing.(7) Remove driver's zone actuator from distribution
housing (Fig. 77).
(8) Remove passenger zone actuator from distribu-
tion housing (Fig. 78).
Fig. 71 Evaporator
Fig. 72 Distribution Housing
Fig. 73 Heater Core Cover
Fig. 74 Heater Core Tube Plate
Fig. 75 Plate Removal
Fig. 76 Heater Core Tube Removal
24 - 36 HEATING AND AIR CONDITIONINGNS
DISASSEMBLY AND ASSEMBLY (Continued)

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

Air from inside the vehicle is drawn into the air
intake grille in the right rear quarter trim panel. The
air enters the blower and is pushed through the
heater core and A/C evaporator coil. The air direc-
tion, floor or overhead, is determined by the position
of the driver's temperature control lever on the front
HVAC system control. If the temperature control
lever is below 20% heat, the auxiliary HVAC system
airflow will come from the overhead air outlets. In
between 20% and 80%, the airflow will remain in the
last position selected. In other words, if the driver
started out in full heat and then adjusted their tem-
perature lever to 30% heat as they became comfort-
able, the rear air would come out the floor outlets the
whole time.
Fig. 2 Front Lines Connected to Rear Lines
Fig. 3 Rear Heater Hose Connection
Fig. 4 Rear heater hose quick connects
Fig. 5 Rear A/C Block Connection
Fig. 6 A/C Control Panel
24 - 42 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)