heater CHRYSLER VOYAGER 1996 Service Manual

DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When diagnosing electrical problems in the auxil-
iary rear heater or rear A/C system, refer to Group
8W, Wiring Diagrams.
When diagnosing problems in the auxiliary sys-
tems, refer to diagnostic sections for front heater A/C.
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT-A/C
REMOVAL
(1) Remove quarter trim panel, D-pillar, and head-
liner (Fig. 8). Refer to Group 23, Body.
(2) Remove screws securing D-pillar duct to quar-
ter panel. Pull duct up and away from unit.
(3) Remove screws securing duct to rear header
(Fig. 9).
(4) Remove screws securing duct to right and left
rails (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
AIR DISTRIBUTION DUCT-HEATER
REMOVAL
(1) Remove quarter trim panel and D-pillar (Fig.
8) and (Fig. 11). Refer to Group 23, Body.
(2) Remove screws securing lower heat duct to
housing.
INSTALLATION
For installation, reverse the above procedures.
Fig. 7 Rear Blower Switch
Fig. 8 Quarter Trim Panel
Fig. 9 Rear Crossover Duct
Fig. 10 Upper A/C Duct
NSHEATING AND AIR CONDITIONING 24 - 43
DESCRIPTION AND OPERATION (Continued)

CAUTION: Do not damage the evaporator insulation
liner during installation.
(3) Carefully install the evaporator and expansion
valve straight into the unit. Do not scratch the seal-
ing surfaces with the plumbing extension tube pilots.
(4) Determine the amount of old refrigerant oil
drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system.
(5) Carefully align the expansion valve onto the
pilot tubes of the plumbing extension (do not scratch
the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten
bolts to 2363 N´m (200630 inch pounds) torque.
(6) Install evaporator cover and blower scroll.
(7) Install quarter trim panel, evacuate/charge sys-
tem, and perform the performance test.
REAR AIR CONDITIONING LINES
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Hoist vehicle
(2) Remove compression fittings to the suction and
liquid lines located on the right, outboard side of the
underbody, rearward of the front crossmember. (Fig.
2)
(3) remove (1) bolt securing a/c lines to block
located on the right, outboard side of the underbody,
rearward of the rear wheel and tire. (Fig. 5)
(4) Remove (3) straps securing underbody lines.
(Fig. 1)
(5) Separate and remove a/c lines from vehicle.
INSTALLATION
(1) Before installation, replace all O-rings and gas-
kets. Coat all sealing surfaces with approved wax-
free refrigerant oil. Then, reverse the above
procedures.
(2) Evacuate and recharge system.
REAR HEATER A/C AIR OUTLETS
REMOVAL
Separate barrel from bezel by pulling outward.
INSTALLATION
For installation, push the outlet firmly into the
opening until it locks into place.
REAR HEATER-A/C AUXILIARY CONDENSER
If vehicle is equipped with a 3.3L or 3.8L engine
with rear heater and air conditioning, it will be
equipped with an auxiliary condenser. The auxiliarycondenser is mounted on the primary condenser in
front of the radiator. Both condenser must be
removed as an assembly and then separated.
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
NOTE: Special effort must be used to keep all
R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a
reliability problem with the compressor.
The condenser assembly must first be removed
from vehicle. Refer to CONDENSER ASSEMBLY
removal and installation in this section for service
procedures.
REMOVAL
(1) After condenser assembly removal, place on
bench for disassembly.
(2) Remove (1) bolt to liquid line on auxiliary con-
denser.
(3) Remove (4) attaching bolts and separate auxil-
iary from primary condenser. (Fig. 15)
INSTALLATION
(1) Before installation, replace all O-rings and gas-
kets. Coat all sealing surfaces with approved wax-
free refrigerant oil. Then, reverse the above
procedures.
(2) Evacuate and recharge system.
Fig. 15 3.3L/3.8L REAR HEAT-A/C AUXILIARY
CONDENSER
NSHEATING AND AIR CONDITIONING 24 - 45
REMOVAL AND INSTALLATION (Continued)

REAR HEATER A/C BLOWER MOTOR
REMOVAL
(1) Remove the right quarter trim panel and D-pil-
lar trim. Refer to Group 23, Body for service proce-
dures.
(2) Remove (5) screws securing the blower motor
housing to the rear of the HVAC housing (one screw
located on evaporator cover) (Fig. 16).
(3) Twist motor out of scroll housing.
(4) Disconnect blower motor wiring connector.
INSTALLATION
For installation, reverse the above procedures.
REAR HEATER-A/C CONTROL ILLUMINATION BULB
REMOVAL
(1) Remove rear heater-A/C control from trim
panel.
(2) On the back of control opposite from the wire
connectors, locate the bulb socket lug.
(3) Rotate the socket counterclockwise and pull the
socket from the control.
INSTALLATION
For installation, reverse the above procedures.
Refer to Group 8L, Lamps for bulb usage.
REAR HEATER A/C UNIT
NOTE: Special effort must be used to keep all
R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a
reliability problem with the compressor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR
A/C, THE REFRIGERANT SYSTEM MUST BE EMP-
TIED BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Using a refrigerant recovery machine, remove
refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit.
(2) Hoist vehicle.
(3) Remove A/C lines at lower floor pan flange
(Fig. 17).
(4) Remove (3) A/C unit floor mounting nuts (Fig.
18).
(5) Lower vehicle.
(6) Remove right quarter trim panel and D-pillar
trim (Fig. 8). Refer to Group 23, Body.
(7) Remove screws securing air distribution duct to
the rear wheel housing (Fig. 19).
Fig. 16 Blower Motor
Fig. 17 A/C Lines
Fig. 18 A/C Mounting
24 - 46 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

(8) Pinch off heater lines at heater core hookup
(Fig. 20).
(9) Remove heater hoses at heater core (Fig. 21).(10) Remove quarter trim panel mounting bracket
(Fig. 22).
(11) Remove blower motor wiring harness connec-
tor.
(12) Remove rear upper duct trim screw (Fig. 23).
(13) Remove (2) Heater-A/C housing mounting
bolts (Fig. 24).
(14) Pull up on upper A/C duct. Tilt A/C unit out-
ward (Fig. 25).
(15) Lift the unit enough to clear floor pan.
Remove unit from the vehicle.
INSTALLATION
For installation, reverse the above procedures.
Install new O-rings at refrigerant lines. Evacuate
and charge the refrigerant system. Fill the heater
core (Fig. 26). Test for leaks and overall performance.
Fig. 19 Lower Heater Duct
Fig. 20 Heater Core Lines
Fig. 21 Heater Hoses
Fig. 22 Trim Panel Mounting Bracket
Fig. 23 Upper Duct Trim
NSHEATING AND AIR CONDITIONING 24 - 47
REMOVAL AND INSTALLATION (Continued)

NOTE: If the heater core was emptied and was not
prefilled, it is necessary to thermal cycle the vehicle
TWICE. The heater core is positioned higher than
the radiator fill cap. Therefore the heater core will
not gravity fill to level. To thermal cycle the vehicle,
it must be operated till the thermostat opens, then
turned off and allowed to cool. In order to verify
that the auxiliary unit is filled completely, the follow-
ing procedure can be used:
²Vehicle at room temperature.
²Engine is brought up to operating temperature.
²Front unit is OFF, temperature slides are at full
HEAT position.
²Engine is at idle.
²With rear blower motor ON HIGH.
²Discharge air temperature, measured at the
dual register located on the C-pillar base, is between
135É and 145É F.
REAR HEATER CORE
REMOVAL
(1) Remove the lower right quarter trim panel.
Refer to Group 23, Body.
(2) Isolate and disconnect lines from heater core
(Fig. 27).
(3) Remove heater core retaining screws.
(4) Carefully pull the heater core and tubes up and
straight out of the unit.
INSTALLATION
For installation, reverse the above procedures. Pre-
fill the heater core (Fig. 26). Test for leaks and over-
all performance.
Fig. 24 Mounting Bolts
Fig. 25 A/C Unit Replacement
Fig. 26 Filling Heater Core
Fig. 27 Heater Core Lines
24 - 48 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

NOTE: If the heater core was emptied and was not
prefilled, it is necessary to thermal cycle the vehicle
TWICE. The heater core is positioned higher than
the radiator fill cap. Therefore the heater core will
not gravity fill to level. To thermal cycle the vehicle,
it must be operated till the thermostat opens, then
turned off and allowed to cool. In order to verify
that the auxiliary unit is filled completely, the follow-
ing procedure can be used:
²Vehicle at room temperature.
²Engine is brought up to operating temperature.
²Front unit is OFF, temperature slides are at full
HEAT position.
²Engine is at idle.
²With rear blower motor ON HIGH
²Discharge air temperature, measured at the
dual register located on the C-pillar base, is between
57ÉC to 62ÉC (135É and 145É F).
REAR HEATER LINES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Partially drain engine cooling system. Refer to
Group 7, Engine Cooling.
(2) Loosen clamp at the front end of the hose
located at the right, outboard side of the underbody,
rearward of the front crossmember. (Fig. 2)
(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.
CAUTION: When removing hoses from outlet nip-
ples, do not use excessive force. Outlet nipples
may become damaged and leak engine coolant.
(4) Compress insert in rear heater hose quick con-
nection and pull downward on hose. (Fig. 4)(5) Remove (3) straps securing underbody lines.
(Fig. 1)
(6) Separate and remove rear heater lines from
vehicle.
INSTALLATION
For installation, reverse the above procedures.
MODE DOOR
REMOVAL
(1) Remove A/C unit.
(2) Place unit on bench.
(3) Remove heater core.
(4) Remove blower scroll.
(5) Remove evaporator cover.
(6) Remove A/C line to expansion valve mounting
nut.
(7) Carefully pull evaporator out of housing.
(8) Remove mode door actuator and gear exten-
sion.
(9) Remove Heater-A/C housing clips and screws.
(10) Separate housing halves.
(11) Remove mode door.
INSTALLATION
For installation, reverse the above procedures.
MODE DOOR ACTUATOR
REMOVAL
(1) Remove A/C unit.
(2) Place unit on bench.
(3) Remove mode door actuator connector.
(4) Remove mode door actuator mounting screws
and remove actuator.
INSTALLATION
For installation, reverse the above procedures.
NSHEATING AND AIR CONDITIONING 24 - 49
REMOVAL AND INSTALLATION (Continued)

HEATING AND AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
SAFETY PRECAUTIONS AND WARNINGS.... 2
DESCRIPTION AND OPERATION
A/C PRESSURE TRANSDUCER............ 2
A/C SERVICE PORTS.................... 2
AIR DISTRIBUTION DUCTS............... 2
COMPRESSOR......................... 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................ 3
SIDE DOOR HEATER A/C OUTLETS........ 4
SIDE WINDOW DEMISTER............... 4
SYSTEM AIRFLOW..................... 4
SYSTEM OIL LEVEL..................... 4
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST............... 11
A/C PRESSURE TRANSDUCER........... 11
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST..................... 5
BLOWER MOTOR AND WHEEL ASSEMBLY . 12
COMPRESSOR CLUTCH/COIL............ 12
COMPRESSOR NOISE DIAGNOSIS........ 12
EXPANSION VALVE.................... 14
HEATER PERFORMANCE TEST........... 14
HVAC CONTROL DIAGNOSTIC CONDITIONS . 9
SYSTEM CHARGE LEVEL TEST........... 15SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM....... 17
EVACUATING REFRIGERANT SYSTEM..... 17
R-134a REFRIGERANT.................. 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS.......................... 18
SYSTEM LEAK CHECKING............... 19
THERMOCOUPLE PROBE............... 18
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER........... 19
A/C SERVICE PORTS................... 19
BLEND-AIR DOOR ACTUATOR........... 20
BLOWER MOTOR AND WHEEL ASSEMBLY . 20
BLOWER MOTOR RESISTOR BLOCK...... 21
BLOWER MOTOR WHEEL............... 22
COMPRESSOR (2.5L TURBO DIESEL)..... 22
CONDENSER ASSEMBLY................ 23
DISCHARGE LINE..................... 23
EVAPORATOR PROBE.................. 24
EXPANSION VALVE.................... 25
FILTER-DRIER ASSEMBLY............... 26
HEATER A/C UNIT HOUSING............. 26
HEATER CORE........................ 26
HEATER HOSES....................... 28
LIQUID LINE......................... 28
MODE DOOR ACTUATOR................ 29
RECIRC DOOR ACTUATOR.............. 30
SIDE WINDOW DEMISTER DUCTS........ 29
SUCTION LINE........................ 29
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION......... 30
GENERAL INFORMATION
INTRODUCTION
The Heater, or Heater and Air Conditioning sys-
tems 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 Heater
A/C 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.
NS/GSHEATING AND AIR CONDITIONING 24 - 1

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 OR
INHALED. 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 arenot 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. The High Side (Discharge) valve ser-
vice port is located on the liquid line near the right
strut tower. The Low Side (Suction) valve service
port is located on the suction line near the compres-
sor.
The High Side service port is a two piece port and
is serviceable. The Low Side service port is not ser-
viceable, and the suction line would have to be
replaced.
COMPRESSOR
The A/C compressor for the 2.5L Turbo Diesel, is
located on the front side of the engine block. It is
mounted to the engine block by four bolts. The com-
Fig. 1 A/C Pressure Transducer
24 - 2 HEATING AND AIR CONDITIONINGNS/GS
GENERAL INFORMATION (Continued)

and washer operation, front & rear window defogger,
recirculation door operation, and A/C compressor
operation if equipped. Refer to Group 8E, Instrument
Panel and Systems for service procedures.
The rear blower speed switch is serviced separately
from the control head.
SIDE DOOR HEATER A/C OUTLETS
The driver's and passenger side doors have supple-
mental air outlets and duct work. The air is chan-
neled from the instrument panel to the door duct and
either to the lower floor or upper door outlets (Fig.
3). The air can be adjusted to blow on the first rear
passenger seat(s).
SIDE WINDOW DEMISTER
The side window demisters direct air from the
heater assembly. The outlets are located on the top
forward corners of the front door panels (Fig. 4). The
demisters operate when the control mode selector is
on FLOOR, MIX or DEFROST setting.
SYSTEM AIRFLOW
The system pulls outside (ambient) air through the
cowl opening at the base of the windshield. Then it
goes into the plenum chamber above the heaterÐA/C
unit housing. On air conditioned vehicles, the air
passes through the evaporator. At this point the air
flow can be directed either through or around the
heater core. This is done by adjusting the blend- air
door with the TEMP control on the control head. An
optional zone control HVAC control module is available.
This unit has dual blend-air doors that can be regu-
lated independently of each other. The temperature set-
ting can be different from driver's side to passenger
side. After the air passes the blend-air door(s), the air
flow can then be directed from the Panel, Floor, and
Defrost outlets. Air flow velocity can be adjusted with
the blower speed selector switch on the control head.
Ambient air intake can be shut off by closing the
recirculating air door. This will recirculate the air
that is already inside the vehicle. This is done by
depressing the Recirc. button on the control head. On
air conditioned vehicles, moving the control to Mix or
Defrost depresses the A/C button and will engage the
compressor. This will send refrigerant through the
evaporator, and remove heat and humidity from the
air before it goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
Fig. 2 HVAC Control Module
Fig. 3 Door Outlets
Fig. 4 Demister Inlet
24 - 4 HEATING AND AIR CONDITIONINGNS/GS
DESCRIPTION AND OPERATION (Continued)

capacity of the system and consequently result in
higher discharge air temperatures.
NOTE: The oil used in the Denso 2.5L Turbo Diesel
and the Denso 2.0L gasoline engine compressors is
ND-8 PAG R134a refrigerant oil. Only refrigerant oil
of the same type should be used to service the sys-
tem. Do not use any other oil. The oil container
should be kept tightly capped until it is ready for
use. Tightly cap afterwards to prevent contamina-
tion from dirt and moisture. Refrigerant oil will
quickly absorb any moisture it comes in contact
with. Special effort must be used to keep all R-134a
system components moisture-free. Moisture in the
oil is very difficult to remove and will cause a reli-
ability problem with the compressor.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and
components. The evaporator, condenser, and filter-
drier will retain a significant amount of oil, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent is replaced, the specified amount of refrigerant
oil must be added. When the compressor is replaced,
the amount of oil that is retained in the rest of the
system must be drained from the replacement com-
pressor. When a line or component has ruptured and
oil has escaped, the compressor should be removed
and drained. The compressor is drained through the
suction port or by removing the sump bolt on top of
the compressor, refer to Compressor Removal and
Installation procedures. The filter-drier must be
replaced along with the ruptured part. The oil capac-
ity of the system, minus the amount of oil still in the
remaining components, can be measured and poured
into the suction port of the compressor.
Example: The evaporator retains 50 ml (1.7 oz.).
The condenser retains 30 ml (1 oz) of oil, and system
capacity may be 220 ml (7.40 oz) of oil.
220 ml minus 90 ml = 130 ml (4.40 oz.).
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 the Denso 2.5L Turbo Diesel and Denso 2.0L gas-
oline engine compressors is ND-8 PAG compressor
oil. For gasoline vehicles still using R-12 refrigerant,
use ND8 PAG compressor oil.
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 calibration.
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibra-
tion compensates for mechanical variations in the
REFRIGERANT OIL CAPACITIES
REFRIGERANT OIL CAPACITIES
COMPONENT ML OZ
Compressor 135 ml 4.5 oz
Filter-Drier 30 ml 1.0 oz
Condenser 30 ml 1.0 oz
Evaporator 50 ml 1.7 oz
NS/GSHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)