instrument panel CHRYSLER VOYAGER 1996 Service Manual

INSTALLATION
(1) Place cowl trim sill plate in position on vehicle.
(2) Engage hidden clips to hold cowl trim to cowl
panel.
(3) Install door sill plate.
FLOOR CARPET
REMOVAL
(1) Remove front seats.
(2) Remove front center console.
(3) Remove first rear seat.
(4) Remove second rear seat.
(5) Remove front cowl panels and sill plates.
(6) Remove sliding door sill plates.
(7) Remove rear door sill plate.
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.(11) Remove floor escutcheons (Fig. 6).
(12) Remove push-in fasteners holding carpet to
floor in front seat area.
(13) Roll carpet from under instrument panel to
center of sliding door.
(14) R
oll carpet forward away from rear door open-
ing.
(15) Extract carpet through sliding door opening
(Fig. 7).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.
(4) Install push-in fasteners through carpet and
grommet into floor to hold carpet to floor in front
seat area.
Fig. 3 Cowl Cover
Fig. 4 Cowl Cover Retainers
Fig. 5 Cowl Trim
Fig. 6 Seat Escutcheons
23 - 26 BODYNS
REMOVAL AND INSTALLATION (Continued)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)

SHOULDER BELT HEIGHT ADJUSTER±BOR
C-PILLAR
REMOVAL
(1) Remove B or C-pillar trim cover.
(2) Remove screws holding shoulder belt height
adjuster to pillar.
(3) Remove height adjuster from vehicle (Fig. 94).
INSTALLATION
For installation, reverse the above procedures.
Tighten seat belt anchor bolts to 39 N´m (29 ft. lbs.)
torque.
SHOULDER BELT HEIGHT ADJUSTER KNOB
REMOVAL
(1) Disengage clips holding clam shell cover to seat
belt turning loop and open cover.
(2) Using a Snap-onttrim tool, pry knob from
shoulder belt height adjuster (Fig. 95).
INSTALLATION
(1) Place shoulder belt height adjuster knob in
position on height adjuster.
(2) Push knob on until retainers engage.
SIDE VIEW MIRROR
REMOVAL
(1) Release front door latch and open door.
(2) Remove screw holding molding to base of side
view mirror (Fig. 96).
(3) Remove molding from mirror.
(4) Remove bolts holding bottom of side view mir-
ror to A-pillar.
(5) Remove bolt attaching top of side view mirror
to A-pillar (Fig. 96).
(6) If equipped, disconnect power side view mirror
wire connector from instrument panel harness.
(7) Remove side view mirror from vehicle.
INSTALLATION
(1) Connect power side view mirror wire connector
into instrument panel harness, if equipped.
(2) Place side view mirror in position on vehicle
(Fig. 96).
(3) Install bolt to hold top of side view mirror to
A-pillar.
(4) Install bolts to hold bottom of side view mirror
to A-pillar.
(5) Place molding in position on mirror.
(6) Install screw to hold molding to base of side
view mirror.
SLIDING DOOR
CAUTION: Apply several layers of masking tape to
the body around the rear end of the upper roller
channel and the forward edge of the quarter panel,
to avoid damaging the paint.
Fig. 94 Shoulder Belt Height Adjuster
Fig. 95 Shoulder Belt Height Adjuster Knob
Fig. 96 Side View Mirror
23 - 64 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

The High Side service port is a two piece port and
is serviceable. The Low Side service port is not ser-
viceable, the suction line would have to be replaced.
REAR BLOWER SPEED SWITCH
The rear blower speed switch controls the rear
blower with the choice of low and high speeds. When
the switch is on it allows the blower speed switch
located on the rear headliner to control rear blower
speed. This switch will override the rear headliner
blower switch. For operation instructions refer to the
Owner's Manual. The rear blower speed switch is
serviced separately from the A/C control module. For
service procedures, refer to Group 8E, Instrument
Panel And Gauges.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The High Pressure Relief Valve prevents damage
to the air conditioning system if excessive pressure
develops. Excessive pressure can be caused by con-
denser air flow blockage, refrigerant overcharge, or
air and moisture in the system.The high pressure relief valve vents only a small
amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the
refrigerant is conserved in the system. The valve is
calibrated to vent at a pressure of 3450 to 4140 kPa
(500 to 600 psi). If a valve has vented a small
amount of refrigerant, it does not necessarily mean
the valve is defective.
The High Pressure Relief Valve is located on the
compressor manifold at the discharge passage.
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.
CONDENSATE DRAIN
Condensation from the evaporator housing is
drained through the dash panel and on to the
ground. This drain must be kept open to prevent
water from collecting in the bottom of the housing.
If the drain is blocked condensate cannot drain,
causing water to back up and spill into the passenger
compartment. It is normal to see condensate drain-
age below the vehicle.
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain ample temperature levels from the
heating-A/C system, the cooling system must be in
proper working order. Refer to Group 0, Lubrication
and Maintenance or Group 7, Cooling System of this
manual.
The use of a bug screen is not recommended. Any
obstructions forward of the condenser can reduce the
effectiveness of the air conditioning system.
EVAPORATOR PROBE
The Evaporator probe is located on the HVAC. The
probe prevents evaporator freeze-up by signaling the
Powertrain Control Module to cycle the compressor
ON and OFF. The probe monitors the temperature of
the refrigerant after expansion.
The evaporator probe is inserted into the evapora-
tor between the coils. The probe is a sealed unit and
cannot be adjusted or repaired. It must be replaced if
found defective.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
Fig. 1 A/C Pressure Transducer
Fig. 2 Valve Service Ports
NSHEATING AND AIR CONDITIONING 24 - 3
DESCRIPTION AND OPERATION (Continued)

absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HVAC CONTROL MODULE
The HVAC control module regulates the operation
of the various actuator motors. The actuator motors
are used to move the mode, blend- air, and RECIRC.
doors (Fig. 3).
The control module is included in the A/C control
head located on the instrument panel. The control
head includes the blower speed switch, rear wiper
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.
NOTE: The RECIRC. function on the HVAC control
module automatically defaults to the OFF position
after a ignition key cycle. To reactivate the RECIRC.
function, the RECIRC. button must be repressedThe 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.
4). 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. 5). 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
Fig. 3 HVAC Control Module
Fig. 4 Door Outlets
24 - 4 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)

probe will drop the temperature 7ÉC (20ÉF) in two
minutes. If the Evaporator Probe is found to be
faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat
test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures table.
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PRESSURE TRANSDUCER
The work area temperature must not be below
10ÉC (50ÉF) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the
wire connector is clean of corrosion and connected
properly.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Install scan tool (DRB):
²Go to main menu
²Select stand alone scan tool (DRB)
²Select refer to the proper year diagnostics
²Select climate control
²Select sensor display
²Select A/C high side volts
For A/C system to operate a voltage between .451
(Low Pressure Cutout) to 4.519 (High Pressure Cut-
out is required. Voltages outside this range indicate a
low or high pressure condition andwill notallow
the compressor to cycle.
Refer to the A/C Pressure Transducer Voltage table
for the appropriate condition(s):
A/C PERFORMANCE TEMPERATURES
AMBIENT TEMPERATURE 21ÉC
(70ÉF)26.5ÉC
(80ÉF)32ÉC
(90ÉF)37ÉC
(100ÉF)43ÉC
(110ÉF)
AIR TEMPERATURE AT LEFT
CENTER PANEL OUTLET1-8ÉC
(34-46ÉF)3-9ÉC
(37-49ÉF)4-10ÉC
(39-50ÉF)6-11ÉC
(43-52ÉF)7-18ÉC
(45-65ÉF)
COMPRESSOR DISCHARGE
PRESSURE AFTER THE FILTER
DRIER1034-1724
kPa
(150-250
PSI)1517-2275
kPa
(220-330
PSI)1999-2620
kPa
(290-380
PSI)2068-2965
kPa
(300-430
PSI)2275-3421
kPa
(330-496
PSI)
EVAPORATOR SUCTION
PRESSURE103-207 kPa
(15-30 PSI)117-221 kPa
(17-32 psi)138-241 kPa
(20-35 PSI)172-269 kPa
(25-39 PSI)207-345 kPa
(30-50 PSI)
24 - 12 HEATING AND AIR CONDITIONINGNS
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)

²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set in 100 percent outside air
²Full Panel Mode
²Blower motor ON HIGH
²A/C in the ON position
²Front Windows Open.
²Rear Air Off (If Equipped)
CAUTION: A leak detector designed for R-12 refrig-
erant will not detect leaks in a R-134a refrigerant
system.
(4) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the recirculating air door opening
or a heat duct.
If a thorough leak check has been completed with-
out indication of a leak, proceed to System Charge
Level-Check or Fill.
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER
REMOVAL
(1) Disconnect the wire connector at the pressure
transducer.
(2) Using an open end wrench, remove the trans-
ducer from the liquid line (Fig. 11).
INSTALLATION
(1) Replace transducer O-ring.
(2) For installation, reverse the above procedures.
A/C SERVICE PORTS
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
The High Side service port is serviceable, the Low
Side is not serviceable.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Recover A/C system refrigerant.
(3) Unscrew the High Side service port from the
liquid line.
(4) Remove O-ring
INSTALLATION
For installation, reverse the above procedures.
²Install new O-ring.
²Evacuate and recharge A/C system.
BLEND-AIR DOOR ACTUATOR
REMOVAL
The air conditioning system can be equipped with
either a standard, single blend-air door actuator, or it
can be equipped with dual actuators. The dual sys-
tem has separate blend-air controls. This allows for
separate control of the driver's side air, and the pas-
senger side air (Fig. 12).
(1) Remove the lower left side steering column
cover. Refer to Group 8E, Instrument Panel and Sys-
tems.
(2) Remove ABS control module (Fig. 13).
(3) Remove blend-air actuator connector.
(4) Remove blend-air actuator (Fig. 14).
INSTALLATION
(1) For installation, reverse the above procedures.
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
24 - 20 HEATING AND AIR CONDITIONINGNS
SERVICE PROCEDURES (Continued)

INSTALLATION
(1) For installation, reverse the above procedures.
Replace all O-rings. Torque discharge line at con-
denser bolt to 180 in. lbs.610.
(2) Evacuate and recharge A/C system.
(3) Perform the HVAC Control Calibration Diag-
nostic and Cooldown test.
EVAPORATOR PROBE
REMOVAL
(1) Remove the glove box. Refer to Group 8E,
Instrument Panel and Systems.
(2) Disconnect the evaporator probe connector (Fig.
36).
(3) Using a flat blade pry tool, pry the evaporator
probe grommet from the HVAC housing (Fig. 37).
(4) Remove evaporator probe from evaporator (Fig.
38).
INSTALLATION
For installation, reverse the above procedures. Three
holes are provided in evaporator for probe location.
When reinstalling probe, use a different hole than orig-
inal one. If a new evaporator is installed, insert the
probe in the uppermost hole provided.
Fig. 34 Compressor Discharge Line
Fig. 35 Condenser Discharge Line
Fig. 36 Evaporator Probe Connector
Fig. 37 Evaporator Probe Grommet
Fig. 38 Evaporator Probe
NSHEATING AND AIR CONDITIONING 24 - 27
REMOVAL AND INSTALLATION (Continued)