air condition CHRYSLER VOYAGER 1996 Manual Online

7C2
POWER
DISTRIBUTION
CENTER
40A
FUSE
21
85
87
3086FRONT
BLOWER
MOTOR
RELAY
5C2
3C1 C42
BLOCK JUNCTION
12FUSE10A
BATT A0
RUN A22
F20
20
WT
1
2
MOTOR BLOWER
FRONT B23
P18
C71
12
DB
Z1
18
BK
C28
5 0
123
4
A/C
HEATER
CONTROL
3C27C2C24C2210C2
C7
12
BK/TN
B35
10 1356
FRONT
BLOWER
MOTOR
RESISTOR
BLOCK
B31B23
P18B30 B33 B34B32C4
16
TN
C5
16
LGC6
14
LBC104
12
RD/WTC107
12
TN/BK
TN/BK12 C107
RD/WT12 C104
LB14 C6
LG16 C5
TN16 C4
HVAC
CONTROL FRONT
BLOWER
OFF GROUND
G300
BK12Z1
C26
G201
7
10
SWITCH CONTROL
FRONT
BLOWER
REAR
Z1
12
BK
4 M3 2 M1
3 M2 1 LOW 0 OFF
5 HIGH
35
32 34 33 30 31
GROUND M
(8W-10-8)
(8W-10-18) (8W-12-2)
(8W-12-12)
(8W-10-8) (8W-10-14)
(8W-15-7)
(8W-15-4)(8W-42-6)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATERNS/GS
J988W-3GS004202

A/C
HEATER
CONTROL
HVAC
CONTROL MODE
SELECTGROUND
4 3
2
15
SENSE CONTROL LEFT TEMP.REAR
WASHER
SWITCH
SENSE
11C1
6C221C1
G201
7SWITCH CONTROL
FRONT
BLOWER
REAR
Z1
12
BK
Z1
12
BK
SENSE SWITCHDELAY
LAMP
ILLUMINATIONREAR
WIPER
DELAY
SWITCH
DELAY ON
INDICATOR
DRIVER
ON DELAY
WIPER
REAR
SWITCH
ON
WIPER
REAR
SWITCH WIPER ON
INDICATOR
REAR
WIPER
ON
INDICATOR DRIVER INDICATORWIPER ON
REAR
WASHER
SWITCH
RIGHT
TEMP.
CONTROL
GROUND
BK/LG18Z2
G200
5
2
PANEL
LAMPS
DRIVERBODY
CONTROL
MODULE
C48
BLOCK JUNCTION
6
CLUSTER
INSTRUMENT
E2
20
OR
E2
20
OR
WASHWIPE/ REAR
C12
38C2
SWITCH WIPEERREAR
V26
22
YL/WT
37
SIGNAL SWITCHA/C
POWERTRAIN
CONTROL
MODULE
SIGNAL SWITCH A/C ON-OFF
C13
C103
20
DG/LB
P18
B23B36
SENSEDRIVER WIPER DE-ICEELECTRIC
ELECTRIC
WIPER
DE-ICER
C17
C66
18
BK/WT
MODULE CONTROL
POWERTRAINA/C
SWITCH
SIGNAL
38C1
1
DG/LB18 C103
E43
B70
GAS DIESEL
C103
20
DG/LB
36
1 PANEL
2 BI-LEVEL
4 MIX 3 FLOOR
5 DEFROST
E2
20
OR
FRONT
CIGAR
LIGHTER/
POWER
OUTLET
TO
1C2
MUX
FEED LAMPSPANELWIPER
DE-ICER
SWITCHED
GROUND
GROUND
(8W-15-4)(8W-42-6)
(8W-15-4) (8W-45-5)
(8W-45-6)(8W-12-2)
(8W-40-4)(8W-30-37) (8W-30-5)
(8W-41-3)(8W-12-23)
NS/GS8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
GS004203J988W-3

A/C
HEATER
CONTROL
HVAC
CONTROL
A/C
ON/OFF
SWITCH
SENSE
21C1
REAR
WINDOW
DEFOGGER
SWITCH
ON DEFOGGER
REAR
SWITCH
MODE
RECIRCULATE
SWITCH SENSEMODEINDICATOR
A/C
ON
INDICATOR DRIVER INDICATORA/C ON
A/C
SWITCH
BK/LG18Z2
G200
5
BLOCK JUNCTION
INDICATOR
MODE
RECIRCULATE
REAR WINDOW
DEFOGGER
RELAY CONTROL
10C1C11
(RUN) IGNITIONFUSED
14C4
BR/PK18 V23
20A
FUSE
6
ST-RUN A21
C14
22
WT/RD
C432
DRIVER INDICATORMODE RECIRCULATE
SWITCH SENSEDEFOGGERWINDOWREAR
10
CENTER
MESSAGE
V23
18
BR/PK
REAR
WINDOW
DEFOGGER
RELAY
8586
RECIRCULATE
(8W-15-4)(8W-12-2)
(8W-12-9)(8W-10-16)
(8W-46-2)
(8W-48-2)
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATERNS/GS
J988W-3GS004204

A/C
HEATER
CONTROL
HVAC
CONTROL
19C1
13C1
COMMONDOORZONE
15
ZONE
DOOR
DRIVER
C115
910
ACTUATOR DOOR
ZONE
234
C61
20
DB
C61
22
DB
P30 J01D
C62
20
DB/PK
C62
22
DB/PK
432
BLEND
DOOR
ACTUATOR
51
LG22 C102
11
4
C1
FEEDBACKDOORZONE
LG20 C102
JS01B
JS02B
4
C33
20
DB/RD
C117C33
22
DB/RD
BLEND
DOOR
DRIVER
SIGNALCOMMONDOOR
12C1
DB/WT22 C34
5
DB/WT20 C34
15 15
ACTUATOR DOOR
RECIRCULATION
24312
ACTUATOR
DOOR
MODE
SENSOR TEMPERATURE
EVAPORATOR
RECIRC.
DOOR
DRIVER
COMMONDOOR
C112
DRIVERDOOR MODE
C118
JS03
8C1
TEMP.
SENSOR
SIGNALEVAP.
C120SENSOR
GROUND
JS01B
6C1
SIGNAL FEEDBACK MODE DOOR
9C1
SUPPLY5V
JS02B
C15
BLEND DOOR
FEEDBACK
SIGNAL
C120
SENSOR
GROUNDSUPPLY5V
C19
C57
20
DB/GYC57
20
DB/GY
C57
20
DB/GY
C57
22
DB/GY
21
C26
22
PK/DB
C26
20
PK/DBC26
20
PK/DB
C26
20
PK/DB
7
C36
22
RD/WT
C36
20
RD/WT
12P30
J01D281653
C32
22
GY/DB
C32
20
GY/DBC34
20
DB/WT
C34
20
DB/WTC34
20
DB/WT
C34
22
DB/WTC26
22
PK/DBC57
22
DB/GY
C57
20
DB/GY
C57
20
DB/GY
C35
22
DG/YL
C35
20
DG/YL
C21
22
DB/OR
C21
20
DB/OR
C37
22
YL
C37
20
YL
JS03
C34
20
DB/WT
(DUAL
ZONE A/C)
(A/C)(A/C)
MM
MM
A/C
B
(8W-42-6)TO
P34A
(8W-42-6)TO
P34
C34
20
DB/WTC61
20
DB
C26
20
PK/DB
C57
20
DB/GY
(8W-70-10)
(8W-70-10)
(8W-70-9)(8W-70-10)
(8W-70-10)(8W-70-9)
NS/GS8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
GS004205J988W-3

8
1
REAR
BLOWER
REAR
CONTROL
SWITCH SWITCHCONTROL
FRONT
BLOWER
REAR
8
3
3
2 1 00
123
C11
2
BODY
CONTROL
MODULE
PANEL
LAMPS
DRIVERBLOCK JUNCTION
30C4
741523
546
UNIT
HEATER
A/C
REAR
3
C212
20A
FUSE
11
RUN A22
C40
12
BR/WT
BS17
5
12
E2
20
ORE2
20
OR
G201G302
12
A36
P34
B23
A34
C61
20
DBC34
20
DB/WT
Z1
18
BK
33P34
B23
Z1
12
BK
31
C50
12
BK/LGC50
12
BK/LGC60
16
BK/LBC60
16
BK/LB
C60
16
BK/LB
C65
14
BK/ORC70
12
DG
C70
12
DG
C70
12
DG
A35B23 P34
34 36
A31 A3335
M
M
0 OFF
1 LOW
2 MEDIUM
3 HIGH 3 HIGH2 LOW
1 REAR
0 OFF
A (8W-42-5)B (8W-42-5)
A/C HEATER
CONTROL
FROM
CONTROL A/C HEATER
FROM
C34
20
DB/WT
C61
20
DB
(8W-45-5)(8W-12-2)
(8W-12-11)(8W-10-14)
(8W-70-3) (8W-15-4)
(8W-15-13)(8W-12-23)
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATERNS/GS
J988W-3GS004206

C62
POWER
DISTRIBUTION
CENTER
8587
3086A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7C6
1PTC
9A
C130
BLOCK JUNCTION
ST-RUN A21
6C2
F87
18
WT/BK
C261
POWERTRAIN
CONTROL
MODULE5V
SUPPLY
1
2
CLUTCH COMPRESSOR
A/C
G102 ES23
C3
18
DB/BK
Z1
18
BK
Z1
12
BK
64C2
CONTROL CLUTCH RELAYCOMPRESSORA/C
213
TRANSDUCER
PRESSURE
A/C
SIGNAL SWITCH PRESSUREA/C
42C2
SENSOR
GROUND
C243
C13
18
DB/ORES03
K6
18
VT/WT
K6
18
VT/WT
C18
18
DB
6C61C6
ES07
F87
18
WT/BKF87
18
BK/WT
3.3L/3.8L 2.0L
K4
18
BK/LB
ES02
ES21
ES21 FS01
BK/LB18 K4
K4
18
BK/LB
ES21
ES02
2.4L
5E69 F09
ES02
(8W-10-10)
(8W-10-29)(8W-10-8) (8W-12-13)(8W-12-2) (8W-10-16)
(8W-30-5) (8W-15-2) (8W-15-2)(8W-70-7) (8W-12-13)
(8W-70-4)
(8W-70-4)
(8W-70-5) (8W-70-5) (8W-70-6)
(8W-70-6)
(8W-70-5) (8W-12-13)
NS/GS8W-42 AIR CONDITIONING-HEATER
GAS8W - 42 - 7
GS004207J988W-3

POWER
DISTRIBUTION
CENTER
C2
73
POWERTRAIN
CONTROL
MODULERADIATOR
FAN
RELAY
CONTROL
1
2
NO. 1 FAN
RADIATOR RADIATOR
FAN
NO. 2
2 1
4
3
RELAY FAN
RADIATOR
24FUSE40A
BATT A0
C76
G102RFS2
FUSED
B (+)
FAN
RELAY
CONTROLRELAY
2
RFS1
1E40
RF3
C23
12
DG
C23
12
DG
C23
12
DGC23
12
DG
1 GROUND
ES23
Z1
14
BK
Z1
12
BKZ1
12
BK
Z1
12
BK
E40 RF32
Z1
12
BK
Z1
12
BK
A16
12
GY
MM
LG/DB14 K173
RADIATOR
OUTPUTRADIATOR
FAN
(8W-10-8)
(8W-30-5) (8W-10-15)(8W-10-8)
(8W-15-2)(8W-15-2)
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER
GASNS/GS
J988W-3GS004208

C62
POWER
DISTRIBUTION
CENTER
8587
3086A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7C6
1C6
19
POWERTRAIN
CONTROL
MODULE5V
SUPPLY
CLUTCH COMPRESSOR
A/C
C3
18
DB/BK
28
CONTROL CLUTCH RELAYCOMPRESSORA/C
213
TRANSDUCER
PRESSURE
A/C
SIGNAL SWITCH PRESSUREA/C
13
SENSOR
GROUND 33
C13
20
DB/OR
K7
20
ORC18
20
DBK4
20
BK/LB
2
Z2
18
BK
Z1
16
BK
Z0
10
BK
ES01 ES02Z0
6
BK
G100
Z0
2
BK
G103
BATTERY
30
87
DIESEL
POWER
RELAY
20A
FUSE
17
BATT A0C65
ES29ES06
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
9E97
B106
C13
20
DB/OR
BS34
1(8W-10-9)
(8W-10-29)(8W-10-8)
(8W-30-38) (8W-20-3)
(8W-15-3)
(8W-15-3)(8W-30-28) (8W-10-25)(8W-10-8) (8W-10-25)(8W-10-25)
(8W-70-11)
NS/GS8W-42 AIR CONDITIONING-HEATER
DIESEL8W - 42 - 9
GS004209J988W-3

POWER
DISTRIBUTION
CENTER
6
POWERTRAIN
CONTROL
MODULE
24FUSE40A
BATT A0
C76
A16
12
GY
NO. 1 RELAY
FAN
RADIATOR
6
RADIATOR
FAN
RELAY
NO. 2
48
2662
4
NO. 3 RELAY
FAN
RADIATOR
4
312
ES07
C25
12
YL
LOW
SPEED
RADIATOR
RELAY NO. 2
CONTROLC24
20
DB/PK
CONTROL NO.1 & NO.3RADIATORSPEEDHIGH
48
ES09
1E95
B10710B106 E97ES29
C24
20
DB/PK
C137
20
YLC137
20
YL
C137
20
YL
A142
18
DG/ORA142
18
DG/ORA142
18
DG/OR
C27
12
DB/PKC27
12
DB/PK
C27
12
DB/PK
BATT A17
ES12
G102
Z1
12
BK
Z1
12
BK
Z1
12
BK
C116
12
LG/WT
DRIVER'S
SIDE
RADIATOR
FAN FANRADIATOR
SIDE
PASSENGER'S
MMDISCONNECT
FAN
RADIATOR
48
258A17
12
RD/BK
(8W-10-8)
(8W-30-37)(8W-10-15)(8W-10-8)
(8W-10-25)
(8W-15-3)
(8W-15-3)(8W-10-19)
8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER
DIESELNS/GS
J988W-3GS004210

(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes, using a light honing oil.Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 2).(4) A controlled hone motor speed between
200-300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50-60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
NSENGINE 9 - 3
GENERAL INFORMATION (Continued)