wheel CHRYSLER VOYAGER 1996 Service Manual

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.
The high pressure service port is located on the liq-
uid line near the strut tower. The low pressure ser-
vice port is located on the suction line near the
compressor manifold.
When servicing a system, it is required that an air
conditioning charging recovery/recycling machine be
used (Fig. 8). Contact an automotive service equip-
ment supplier for proper equipment. Refer to the
operating instructions provided with the equipment
for proper operation.
A manifold gauge set (Fig. 9) must also be used in
conjunction with the charging and/or recovery/recy-
cling device. Only use gauges that have not been
used for R-12. The service hoses on the gauge setshould have manual (turn wheel) or automatic back
flow valves at the service port connector ends. This
will prevent refrigerant R-134a from being released
into the atmosphere.
R-134a refrigerant requires a special type of com-
pressor oil. When adding oil, make sure to use the oil
that is specified on the under hood label.
Due to the different characteristics of R-134a it
requires all new service procedures.
Charge Determination Chart
Fig. 8 Refrigerant Recovery/Recycling Station
(Typical)
24 - 16 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)

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.
(2) Perform the HVAC Control Calibration Diag-
nostic and Cooldown test. Repeating the test is nec-
essary to clear the fault codes.
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL
(1) Remove glove box. Refer to Group 8E, Instru-
ment Panel and Systems.
(2) Remove (4) hex head screws to blower motor
cover (Fig. 15).
(3) Disconnect blower motor wiring.
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
Fig. 13 ABS Control Module
Fig. 14 Blend-Air Actuator
24 - 20 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Remove resistor block by inserting a flat blade
pry tool on the side of the resistor block and pushing
inward. Two guide lines are shown on the right hand
edge of the resistor block to help guide the blade
position. This will release the clips on the side of the
resistor block. Pull resistor block out.
INSTALLATION
For installation, reverse the above procedures.
Make sure the ªTOPº lettering is on the top of the
resistor. The coils on the Resistor Block should not be
contacting one another. Before installation, gently
separate the coils (with fingers only) if one coil is
contacting another.
BLOWER MOTOR WHEEL
The blower motor wheel is not serviced separately.
If the wheel needs to be replaced it is serviced as an
assembly of the blower motor. For service procedure
information, refer to Blower Motor Replacement in
this group.
COMPRESSOR (2.5L TURBO DIESEL)
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE
PROCEDURES FOR INFORMATION REGARDING
PROPER RECOVERY OF THE REFRIGERANT
BEFORE ATTEMPTING TO REMOVE THE COM-
PRESSOR.(1) Disconnect negative battery cable.
(2) Reclaim refrigerant.
(3) Raise vehicle on hoist.
(4) Remove refrigerant lines from compressor and
cap all lines (Fig. 10).
(5) Remove flex drive bolts from behind the power
steering pump (Fig. 20).
(6) Remove compressor mounting bolts (Fig. 20).
(7) pry compressor off of the dowel pins and
remove compressor.
INSTALLATION
(1) Transfer mounting spacer/bushings onto the
new compressor.
(2) Lift compressor into place and start compressor
mounting bolts. Do not tighten bolts at this time. The
compressor may have to be moved slightly to align
the flex drive bolts.
(3) Align compressor clutch with flex drive. Then
start both flex drive bolts. Tighten the bolts after
both flex drive bolts have been installed.
(4) Tighten compressor mounting bolts.
(5) Lower vehicle and install refrigerant lines.
Always replace O-rings and gaskets.
(6) Evacuate refrigerant system. Charge system
with the correct amount of R-134a refrigerant. The
refrigerant capacity is .91 kg.67 gm. (32 oz.62.0
oz.).
24 - 22 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (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)

(14) Remove heat door actuator gear (Fig. 67).
(15) Remove distribution housing lower cover
screws (Fig. 68).(16) Remove distribution housing half screws (Fig.
69).
(17) Remove distribution housing front cover (Fig.
70) and (Fig. 71).
Fig. 64 Panel Door Gear
Fig. 65 Defrost Door Gear
Fig. 66 Cam Wheel
Fig. 67 Heat Door Gear
Fig. 68 Distribution Housing
Fig. 69 Distribution Housing Half Screws
24 - 34 HEATING AND AIR CONDITIONINGNS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(24) Remove separator plate from distribution
housing (Fig. 77).
(25) Remove lower half of the blend-air door (Fig.
78).(26) Remove lower half of the Panel door (Fig. 79).
(27) Remove lower half of the Floor door (Fig. 80).
ASSEMBLYÐDISTRIBUTION HOUSING
For reassembly of the distribution housing, reverse
the above procedures.
To reassemble the distribution housing actuator
gears an assembly procedure of the gears and cam is
necessary.
ACTUATOR GEARS ALIGNMENT PROCEDURE
(1) Install lower FLOOR door actuator gear to
housing. Match master spline of FLOOR door actua-
tor gear to master spline on door.
(2) Install cam wheel. Align cam wheel track to
FLOOR door actuator gear.
(3) Align cam wheel slot with the post on the dis-
tribution housing marked ª1º.
Fig. 76 Blend-Air Door
Fig. 77 Separator Plate
Fig. 78 Lower Blend-Air Door
Fig. 79 Lower Panel Door
Fig. 80 Lower Floor Door
24 - 36 HEATING AND AIR CONDITIONINGNS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

(4) Install PANEL door actuator gear. Align master
spline of PANEL door actuator gear to master spline
on PANEL door. Position actuator gear within cam
wheel track.
(5) Install DEFROST door actuator gear to hous-
ing. Match master spline of DEFROST door actuatorto master spline on DEFROST door. Position actuator
gear within cam wheel track.
(6) Reinstall housing in vehicle.
(7) Perform the HVAC control Calibration Diagnos-
tic and Cooldown test.
NS/GSHEATING AND AIR CONDITIONING 24 - 37
DISASSEMBLY AND ASSEMBLY (Continued)

the inlet. This results in maximum vapor flow
through the valve (Fig. 9).
CRANKCASE VENT FILTER
All engines use filtered air to vent the crankcase.
The filtered air is drawn through the resonator
assembly located between the air cleaner and throttle
body.
VEHICLE EMISSION CONTROL INFORMATION
LABEL
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP
Refer to the appropriate Powertrain Diagnostic
Procedures Manual for testing procedures.
PCV VALVE TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
OR ADJUSTMENT WITH THE ENGINE OPERATING.
With the engine idling, remove the PCV valve from
its attaching point. If the valve is operating properly,
a hissing noise will be heard and a strong vacuum
felt when placing a finger over the valve inlet (Fig.
10). With the engine off, shake the valve. The valve
should rattle when shaken. Replace the valve if it
does not operate properly.Do not attempt to clean
the PCV valve.
REMOVAL AND INSTALLATION
LEAK DETECTION PUMP REPLACEMENT
REMOVAL
The Leak Detection Pump (LDP) is located under
the driver's side in the cast cradle under the steering
gear (Fig. 11).
(1) Raise and support vehicle on a hoist.
Fig. 9 Moderate Intake Manifold VacuumÐMaximum
Vapor Flow
Fig. 10 PCV Test ÐTypical
Fig. 11 Leak Detection Pump
25 - 16 EMISSION CONTROL SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

the amount of EGR supplied to the engine. This pro-
vides the correct amount of exhaust gas recirculation
for different operating conditions.
This system does not allow EGR at idle. The EGR
systems can operate at all coolant temperatures
above 60ÉF as long as the battery ambient tempera-
ture is above 7ÉF.
DIAGNOSIS AND TESTING
EGR SYSTEM ON-BOARD DIAGNOSTICS
The PCM performs an on-board diagnostic check of
the EGR system. The diagnostic system uses the
electronic EGR transducer for the system tests.
The diagnostic check activates only during selected
engine/driving conditions. When the conditions are
met, the PCM energizes the transducer solenoid to
disable the EGR. The PCM checks for a change in
the heated oxygen sensor signal. If the air-fuel mix-
ture goes lean, the PCM will attempt to enrichen the
mixture. The PCM registers a Diagnostic Trouble
Code (DTC) if the EGR system is not operating cor-
rectly. After registering a DTC, the PCM turns on the
malfunction indicator (Check Engine) lamp after 2
consecutive trips. There are 2 types of failures sensed
by the PCM. The first is a short or open in the elec-
trical solenoid circuit. The second is a mechanical
failure or loss of vacuum. The Malfunction Indicator
Lamp (MIL) indicates the need for service.
If a problem is indicated by the MIL and a DTC for
the EGR system is set, check for proper operation of
the EGR system. Use the System Test, EGR Gas
Flow Test. If the EGR system tests properly, check
the system using the DRB scan tool. Refer to
On-Board Diagnosis sections in this Group. Also,
refer to the DRB scan tool and the appropriate Pow-
ertrain Diagnostics Procedure manual.
EGR SYSTEM TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE TESTING THE EGR SYS-
TEM.
(1) Check the condition of all EGR system hoses
and tubes for leaks, cracks, kinks and hardening of
rubber hoses. Repair and correct these conditions
before performing any tests.
(2) Be sure the hoses at both the EGR valve and
EGR valve control are connected to the proper fit-
tings (Fig. 4).
(3) Be sure the electrical connector is firmly con-
nected at the valve control.
(4) To check EGR system operation, connect the
DRB scan tool to the 16±way data link connector.
The data link connector is located on the lower edge
of the instrument panel near the steering column.
Refer to the appropriate Powertrain Diagnostic Pro-
cedures service manual for operation of the DRB
scan tool when diagnosing the EGR system.
(5) After checking the system with the DRB scan
tool, proceed to the following EGR Valve Leakage and
EGR Valve Control Tests and repair as necessary.
Fig. 3 Electric EGR Transducer Assembly
Fig. 4 EGR Value and EGR Value ÐTypical
NSEMISSION CONTROL SYSTEMS 25 - 19
DESCRIPTION AND OPERATION (Continued)