service CHRYSLER VOYAGER 1996 Service Manual

BODY
CONTENTS
page page
BODY COMPONENT SERVICE.............. 22
GENERAL SERVICE INFORMATION........... 1
PAINT.................................. 2SEATS .................................. 9
STATIONARY GLASS....................... 4
GENERAL SERVICE INFORMATION
INDEX
page
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS...... 1
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Chrysler Corporation uses many different types of
push-in fasteners to secure the interior and exterior
trim to the body. Most of these fasteners can be
reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
NSBODY 23 - 1

BUCKET SEAT RECLINER ± POWER
REMOVAL
(1) Remove seat cushion pan.
(2) Remove nut holding seat back frame to
recliner.
(3) Using a suitable punch, remove roll pin holding
recliner to seat track (Fig. 14).
(4) Remove recliner from seat track.
(5) Remove recliner from stud on seat back frame.
(6) Disconnect wire connector from power recliner.
(7) Remove power recliner from seat.
INSTALLATION
(1) Place power recliner in position on seat.
(2) Connect wire connector into power recliner.
(3) Insert stud on seat back through hole in
recliner.
(4) Place recliner in position on seat track.
(5) Install roll pin to attach recliner to seat track
(Fig. 14).
(6) Install nut to hold seat back frame to recliner.
(7) Install seat cushion pan.
BUCKET SEAT RISER ± MANUAL TRACK
REMOVAL
(1) Remove seat from vehicle.
(2) If equipped, remove storage bin from riser.
(3) Remove nuts holding riser to manual seat
track (Fig. 15).
(4) Remove riser from seat.
INSTALLATION
(1) Place riser in position on seat.
(2) Install nuts to hold riser to manual seat track
(Fig. 15).
(3) If equipped, install storage bin into riser.
(4) Install seat into vehicle.
BUCKET SEAT TRACK ± MANUAL
REMOVAL
(1) Remove seat from vehicle.
(2) Remove seat cushion pan.
(3) Remove riser.
(4) On inboard track, remove nut holding recliner
to seat back frame.
(5) Remove bolt holding seat back frame to seat
track (Fig. 16).
(6) Remove seat track from seat adjuster handle
(Fig. 17).
(7) Remove seat track from seat.
INSTALLATION
(1) Place seat track in position on seat.
(2) Place adjuster handle in position on seat track
(Fig. 17).
(3) Insert stud on seat back frame into recliner.
(4) Install bolt to hold seat back frame to seat
track (Fig. 16).
(5) On inboard track, install nut to hold recliner to
seat back frame.
(6) Install riser.
(7) Install seat cushion pan.
(8) Install seat in vehicle.
BUCKET SEAT TRACK ± POWER
The power seat track and motors are serviced as
an assembly.
REMOVAL
(1) Remove seat from vehicle.
(2) Remove seat cushion pan.
(3) Remove nut holding recliner to seat back
frame.
(4) Remove bolts holding seat back frame to seat
track.
(5) Remove stud on seat back frame from recliner.
Fig. 14 Bucket Seat Recliner ± Power
Fig. 15 Bucket Seat Riser ± Manual Track
23 - 14 BODYNS
REMOVAL AND INSTALLATION (Continued)

BODY COMPONENT SERVICE
INDEX
page page
DIAGNOSIS AND TESTING
WATER LEAKS.......................... 23
WIND NOISE........................... 24
SERVICE PROCEDURES
HEAT STAKING......................... 24
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM........ 25
A-PILLAR TRIM PANEL................... 25
COWL COVER.......................... 25
COWL TRIM............................ 25
FLOOR CARPET........................ 26
FRONT DOOR APPLIQUE................. 28
FRONT DOOR CHECK STRAP.............. 28
FRONT DOOR FRAME CLOSEOUT MOLDINGS . 29
FRONT DOOR GLASS RUN WEATHER-STRIP . . 30
FRONT DOOR GLASS.................... 29
FRONT DOOR HINGE.................... 30
FRONT DOOR INNER BELT MOLDING....... 31
FRONT DOOR LATCH STRIKER............ 32
FRONT DOOR LATCH.................... 31
FRONT DOOR LOCK CYLINDER............ 32
FRONT DOOR OUTER BELT MOLDING....... 33
FRONT DOOR OUTSIDE HANDLE........... 33
FRONT DOOR REFLECTOR............... 34
FRONT DOOR SILL PLATE................ 34
FRONT DOOR TRIM PANEL................ 34
FRONT DOOR WEATHER-STRIP............ 36
FRONT DOOR WINDOW CRANK............ 36
FRONT DOOR WINDOW REGULATOR....... 36
FRONT DOOR.......................... 27
FRONT SEAT........................... 37
FRONT WHEELHOUSE SPLASH SHIELD..... 37
FUEL FILL DOOR BLOCKER LATCH STRIKER . . 38
FUEL FILL DOOR BLOCKER LATCH......... 38
FUEL FILL DOOR BLOCKER LOCKOUT LINK . . 38
FUEL FILLER HOUSING ± WITH BLOCKER
LATCH .............................. 39
GRILLE............................... 39
HEADLINING........................... 39
HOOD HINGE.......................... 41
HOOD LATCH STRIKER................... 42
HOOD LATCH.......................... 41
HOOD RELEASE CABLE.................. 42
HOOD RELEASE HANDLE................. 42
HOOD................................ 40
JACK STORAGE COVER.................. 43
LEFT D-PILLAR TRIM PANEL............... 43
LEFT QUARTER TRIM PANEL.............. 44
LIFTGATE CHMSL ACCESS PANEL.......... 47
LIFTGATE HINGE........................ 47LIFTGATE LATCH STRIKER................ 47
LIFTGATE LATCH........................ 47
LIFTGATE LOCK CYLINDER............... 48
LIFTGATE OUTSIDE HANDLE.............. 48
LIFTGATE PROP ASSEMBLY............... 49
LIFTGATE SILL PLATE.................... 49
LIFTGATE STABILIZER WEDGE STRIKER..... 49
LIFTGATE STABILIZER WEDGE............. 49
LIFTGATE TRIM PANEL................... 50
LIFTGATE UPPER FRAME MOLDING........ 50
LIFTGATE UPPER FRAME SIDE MOLDINGS . . . 51
LIFTGATE............................. 46
LOWER B-PILLAR TRIM COVER............ 51
LUGGAGE RACK CROSSBAR.............. 51
LUGGAGE RACK RISER COVER............ 52
LUGGAGE RACK SIDE RAIL............... 52
OVERHEAD GRAB-HANDLES.............. 52
QUARTER GLASS....................... 52
QUARTER TRIM BOLSTER................ 53
RADIATOR CLOSURE PANEL CROSSMEMBER . 53
RAIL LAMP MODULE..................... 54
REAR HEADER TRIM..................... 55
REAR HVAC LOUVER AND BEZEL.......... 55
RIGHT D-PILLAR TRIM PANEL.............. 55
RIGHT QUARTER TRIM PANEL............. 56
ROOF APERTURE (RAP) MOLDING.......... 57
SEAT BELT BUCKLE FIRST REAR QUAD
BUCKET............................. 58
SEAT BELT BUCKLE FIRST REAR ± TWO
PASSENGER BENCH................... 58
SEAT BELT BUCKLE SECOND REAR ± THREE
PASSENGER BENCH................... 59
SEAT BELT BUCKLE ± FRONT INBOARD..... 57
SEAT BELT FIRST REAR ANCHOR BRACKET ±
LWB ................................ 59
SEAT BELT FIRST REAR OUTBOARD ± LWB
FOUR DOOR.......................... 60
SEAT BELT FIRST REAR OUTBOARD ± SWB
FOUR DOOR.......................... 60
SEAT BELT LEFT FIRST REAR OUTBOARD ±
LWB THREE DOOR..................... 61
SEAT BELT LEFT FIRST REAR OUTBOARD ±
SWB THREE DOOR.................... 61
SEAT BELT SECOND REAR OUTBOARD ±
SWB ................................ 61
SEAT BELT SECOND RIGHT REAR OUTBOARD
±LWB ............................... 62
SEAT BELT ± OUTBOARD FRONT........... 59
SECOND RIGHT REAR OUTBOARD SEAT BELT
± LWB W/REAR HVAC................... 62
23 - 22 BODYNS

Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during highcrosswinds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If component
alignment or sealing is necessary, refer to the appro-
priate section of this group for proper procedures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
SERVICE PROCEDURES
HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
23 - 24 BODYNS
DIAGNOSIS AND TESTING (Continued)

may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove screw holding A-pillar extension to
door hinge pillar.
(3) Remove A-pillar extension trim from vehicle
(Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle.
(2) Install screw to hold A-pillar extension to door
hinge pillar.
(3) Install instrument panel side cover.
A-PILLAR TRIM PANEL
REMOVAL
(1) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(2) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.
COWL COVER
WARNING: No fingers or tools should be put under
the cowl cover while the wiper motor is operating.
REMOVAL
(1) Remove wiper arms. Refer to Group 8K, Wind-
shield Wipers and Washers for proper procedures.
(2) Remove screws holding lower area of cowl cover
to wiper module (Fig. 3).
(3) Disengage quarter turn fasteners holding outer
ends of cowl cover to wiper module.
(4) Release hood latch and open hood.
(5) Remove wing nuts holding front of cowl cover
to wiper module.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 4).
(7) Lift cowl cover upward enough to gain access to
right washer hose.
(8) D
isconnect washer hose from right washer nozzle.
(9) Close hood. Do not latch.
(10) Remove cowl cover from vehicle.
INSTALLATION
For installation, reverse the above procedures.
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 5).
(3) Remove cowl trim from vehicle.
Fig. 1 A-pillar Lower Extension Trim
Fig. 2 A-pillar Trim
NSBODY 23 - 25
SERVICE PROCEDURES (Continued)

BODY
CONTENTS
page page
BODY COMPONENT SERVICE............... 3 SEATS .................................. 1
SEATS
INDEX
page page
REMOVAL AND INSTALLATION
BENCH SEAT BACK COVER................ 2
HEAD RESTRAINT ESCUTCHEON........... 1HEAD RESTRAINT SLEEVE................. 2
HEAD RESTRAINT........................ 1
REMOVAL AND INSTALLATION
HEAD RESTRAINT
REMOVAL
(1) Lift head restraint to top of travel.
(2) Depress lock button on side of sleeve at top of
seat back (Fig. 1).
(3) Pull head restraint from top of seat back.
INSTALLATION
(1) Position head restraint to seat.
(2) Depress lock button on side of sleeve at top of
seat back.
(3) Insert head restraint into sleeves at top of seat
back.
HEAD RESTRAINT ESCUTCHEON
REMOVAL
(1) Remove head restraint from seat.
(2) Remove escutcheon from head restraint sleeve
(Fig. 2).
(3) Remove head restraint retainer from sleeve.
(4) Separate escutcheon and retainer from vehicle.
INSTALLATION
(1) Position escutcheon and retainer to seat.
(2) Install retainer to sleeve.
(3) Install escutcheon to sleeve.
(4) Install head restraint to seat.
Fig. 1 Head RestraintÐBucket Seat
NS/GSBODY 23 - 1

BODY COMPONENT SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE.................... 3LIFTGATE CHMSL ACCESS PANEL........... 3
REMOVAL AND INSTALLATION
GEARSHIFT CONSOLE
REMOVAL
(1) Lift the parking brake lever to the full up posi-
tion (Fig. 1).
(2) Carefully pull the base of the gearshift boot off
the top of the gearshift console.
(3) Remove the four (4) screws from the top of the
gearshift console (Fig. 2).
(4) Tilt the gearshift boot and carefully push the
boot through the opening in the gearshift console.
(5) Separate console from vehicle.
INSTALLATION
(1) Tilt the gearshift boot and carefully push the
boot through the gearshift console.
(2) Install screws to hold gearshift console to gear-
shift mechanism.
(3) Install gearshift boot and carefully push the
clips into the three (3) slots in the gearshift console.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clip
holding CHMSL access panel to liftgate trim panel
(Fig. 3).
(2) Disengage hooks on CHMSL access cover from
liftgate trim panel.
(3) Separate access panel from vehicle.
Fig. 1 Console, Parking Brake Lever, and Gearshift
Boot
Fig. 2 Gearshift Console and Boot Removal
NS/GSBODY 23 - 3

HEATING AND AIR CONDITIONING
CONTENTS
page page
FRONT HEATING AND AIR CONDITIONING
SYSTEM............................... 1REAR HEATING AND AIR CONDITIONING
SYSTEM.............................. 41
FRONT HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 2
SAFETY PRECAUTIONS AND WARNINGS...... 2
DESCRIPTION AND OPERATION
A/C PRESSURE TRANSDUCER.............. 2
A/C SERVICE PORTS..................... 2
AIR DISTRIBUTION DUCTS................. 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................. 4
REAR BLOWER SPEED SWITCH............ 3
SIDE DOOR HEATER A/C OUTLETS.......... 4
SIDE WINDOW DEMISTER................. 4
SYSTEM AIRFLOW....................... 4
SYSTEM OIL LEVEL...................... 5
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST................ 12
A/C PRESSURE TRANSDUCER............. 12
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST...................... 6
BLOWER MOTOR AND WHEEL ASSEMBLY.... 13
COMPRESSOR CLUTCH/COIL.............. 13
COMPRESSOR NOISE DIAGNOSIS.......... 13
EXPANSION VALVE...................... 13
HEATER PERFORMANCE TEST............ 15
HVAC CONTROL DIAGNOSTIC CONDITIONS . . . 9
SYSTEM CHARGE LEVEL TEST............ 16SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM........ 17
EVACUATING REFRIGERANT SYSTEM....... 18
R-134a REFRIGERANT................... 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS............................ 19
SYSTEM LEAK CHECKING................ 19
THERMOCOUPLE PROBE................. 19
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER............. 20
A/C SERVICE PORTS.................... 20
BLEND-AIR DOOR ACTUATOR............. 20
BLOWER MOTOR AND WHEEL ASSEMBLY.... 21
BLOWER MOTOR RESISTOR BLOCK........ 21
BLOWER MOTOR WHEEL................. 22
COMPRESSOR CLUTCH/COIL.............. 23
COMPRESSOR......................... 23
CONDENSER ASSEMBLY................. 25
DISCHARGE LINE....................... 26
EVAPORATOR PROBE.................... 27
EXPANSION VALVE...................... 28
FILTER-DRIER ASSEMBLY................. 28
HEATER A/C UNIT HOUSING............... 29
HEATER CORE......................... 30
HEATER HOSES........................ 31
LIQUID LINE........................... 32
MODE DOOR ACTUATOR................. 32
RECIRC DOOR ACTUATOR................ 34
SIDE WINDOW DEMISTER DUCTS.......... 33
SUCTION LINE.......................... 33
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION........... 34
NSHEATING AND AIR CONDITIONING 24 - 1

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)