heater CHRYSLER VOYAGER 1996 Service Manual

(7) Remove suction line mounting nut at compres-
sor (Fig. 10).
(8) Remove suction line mounting bracket.
(9) Remove suction line.
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.
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. 45).(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. 46).
(3) Remove blower motor cover (Fig. 47).
Fig. 44 Right Side Demister Duct
Fig. 45 Recirculation Door Actuator
Fig. 46 Distribution Housing
Fig. 47 Blower Motor Cover
24 - 30 HEATING AND AIR CONDITIONINGNS/GS
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. 54).
(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.
55).
(2) Remove heater core cover (Fig. 56).(3) Remove heater core tube plate (Fig. 57) and
(Fig. 58).
(4) Remove heater core tubes (Fig. 59).
Fig. 54 Evaporator
Fig. 55 Distribution Housing
Fig. 56 Heater Core Cover
Fig. 57 Heater Core Tube Plate
Fig. 58 Plate Removal
24 - 32 HEATING AND AIR CONDITIONINGNS/GS
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. 60).
(8) Remove passenger zone actuator from distribu-
tion housing (Fig. 61).
(9) Using a long thin flat blade tool, insert tool
through blend-air opening on top of distribution
housing (Fig. 62). Depress clip retaining the driver's
blend-air door drive gear. Pull out on gear and
remove from the housing (Fig. 63).
(10) Remove mode door motor.
(11) Remove Panel door actuator gear (Fig. 64).
(12) Remove defrost door actuator gear (Fig. 65).
(13) Remove cam wheel (Fig. 66).
Fig. 59 Heater Core Tube Removal
Fig. 60 Driver's Zone Actuator
Fig. 61 Passenger Zone Actuator
Fig. 62 Distribution Housing
Fig. 63 Blend-Air Door Drive Gear
NS/GSHEATING AND AIR CONDITIONING 24 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

HEX
CODEGENERIC
SCAN
TOOL
CODEDRB SCAN TOOL
DISPLAYDESCRIPTION OF DIAGNOSTIC
TROUBLE CODE
52* SPD CTRL PWR RLY; or S/C 12v
Driver CKTMalfunction detected with power feed to speed
control servo solenoids.
5A A/C Pressure Sensor Volts Too
HighSensor input voltage is above 4.9 volts.
5B A/C Pressure Sensor Volts Too Low Sensor input voltage is below .098 volts.
60 P1698 No CCD Messages From TCM No messages received from Transmission Control
Module.
61 No CCD Message From Body
Control ModuleNo messages received from Body Control Module.
65* Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel
pump relay control circuit.
66 P0133 Right Bank Upstream O2S Slow
ResponseOxygen sensor response slower than minimum
required switching frequency.
67 P0135 Right Rear (or just) Upstream O2S
Heater FailureUpstream oxygen sensor heating element circuit
malfunction.
69 P0141 Right Rear (or just) Downstream
O2S Heater FailureOxygen sensor heating element circuit malfunction.
6A P0300 Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 P0420 Right Rear (or just) Catalyst
Efficency FailureCatalyst efficiency below required level.
71* P0441 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during
evaporative emission system operation.
72 P1899 P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.
76 P0172 Right Rear (or just) Fuel System
RichA rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 P0171 Right Rear (or just) Fuel System
LeanA lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E P0138 Right Rear (or just) Downstream
O2S Shorted to VoltageOxygen sensor input voltage maintained above the
normal operating range.
80 P0128 Closed Loop Temp Not Reached Engine does not reach 20ÉF within 5 minutes with
a vehicle speed signal.
81 P0140 Right Rear (or just) Downstream
O2S Stays at CenterNeither reich or lean condition detected from the
downstream oxygen sensor.
84 P0121 TPS Voltage Does Not Agree With
MAPTPS signal does not correlate to MAP sensor
89 P0700 EATX Controller DTC Present An automatic transmission input DTC has been set
in the transmission controller. Refer to Group 21.
8A P1294 Target Idle Not Reached Actual idle speed does not equal target idle speed.
25 - 6 EMISSION CONTROL SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

MONITORED SYSTEMS
There are new electronic circuit monitors that
check fuel, emission, engine and ignition perfor-
mance. These monitors use information from various
sensor circuits to indicate the overall operation of the
fuel, engine, ignition and emission systems and thus
the emissions performance of the vehicle.
The fuel, engine, ignition and emission systems
monitors do not indicate a specific component prob-
lem. They do indicate that there is an implied prob-
lem within one of the systems and that a specific
problem must be diagnosed.
If any of these monitors detect a problem affecting
vehicle emissions, the Malfunction Indicator (Check
Engine) Lamp will be illuminated. These monitors
generate Diagnostic Trouble Codes that can be dis-
played with the check engine lamp or a scan tool.
The following is a list of the system monitors:
²EGR Monitor
²Misfire Monitor
²Fuel System Monitor
²Oxygen Sensor Monitor
²Oxygen Sensor Heater Monitor
²Catalyst Monitor
²Evaporative System Leak Detection Monitor
Following is a description of each system monitor,
and its DTC.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
HEX 66, and 7AÐOXYGEN SENSOR (O2S)
MONITOR
Effective control of exhaust emissions is achieved
by an oxygen feedback system. The most important
element of the feedback system is the O2S. The O2S
is located in the exhaust path. Once it reaches oper-
ating temperature 300É to 350ÉC (572É to 662ÉF), the
sensor generates a voltage that is inversely propor-
tional to the amount of oxygen in the exhaust. The
information obtained by the sensor is used to calcu-
late the fuel injector pulse width. This maintains a
14.7 to 1 air fuel (A/F) ratio. At this mixture ratio,
the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrous oxide (NOx) from
the exhaust.
The O2S is also the main sensing element for the
EGR, Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following
manners:
²Slow response rate
²Reduced output voltage
²Dynamic shift
²Shorted or open circuitsResponse rate is the time required for the sensor to
switch from lean to rich once it is exposed to a richer
than optimum A/F mixture or vice versa. As the sen-
sor starts malfunctioning, it could take longer to
detect the changes in the oxygen content of the
exhaust gas.
The output voltage of the O2S ranges from 0 to 1
volt. A good sensor can easily generate any output
voltage in this range as it is exposed to different con-
centrations of oxygen. To detect a shift in the A/F
mixture (lean or rich), the output voltage has to
change beyond a threshold value. A malfunctioning
sensor could have difficulty changing beyond the
threshold value.
HEX 67, 69, 7C, and 7DÐOXYGEN SENSOR
HEATER MONITOR
If there is an oxygen sensor (O2S) DTC as well as
a O2S heater DTC, the O2S fault MUST be repaired
first. After the O2S fault is repaired, verify that the
heater circuit is operating correctly.
Effective control of exhaust emissions is achieved
by an oxygen feedback system. The most important
element of the feedback system is the O2S. The O2S
is located in the exhaust path. Once it reaches oper-
ating temperature 300É to 350ÉC (572 Éto 662ÉF), the
sensor generates a voltage that is inversely propor-
tional to the amount of oxygen in the exhaust. The
information obtained by the sensor is used to calcu-
late the fuel injector pulse width. This maintains a
14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio,
the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrogen oxide (NOx) from
the exhaust.
The voltage readings taken from the O2S are very
temperature sensitive. The readings are not accurate
below 300ÉC. Heating of the O2S is done to allow the
engine controller to shift to closed loop control as
soon as possible. The heating element used to heat
the O2S must be tested to ensure that it is heating
the sensor properly.
The O2S circuit is monitored for a drop in voltage.
The sensor output is used to test the heater by iso-
lating the effect of the heater element on the O2S
output voltage from the other effects.
HEX 2EÐEGR MONITOR
The Powertrain Control Module (PCM) performs
an on-board diagnostic check of the EGR system.
The EGR system consists of two main components:
a vacuum solenoid and a vacuum operated valve with
a back pressure transducer. The EGR monitor is used
to test whether the EGR system is operating within
specifications. The diagnostic check activates only
during selected engine/driving conditions. When the
25 - 8 EMISSION CONTROL SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)