headlamp CHRYSLER VOYAGER 2001 Service Manual

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer from
the transducer connector receptacle (Fig. 3).
(3) Using an open end wrench, unscrew the A/C
pressure transducer from the fitting on the liquid
line between the filter-drier and the expansion valve.
(4) Remove the seal from the A/C pressure trans-
ducer fitting and discard.
INSTALLATION
(1) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the A/C pressure
transducer fitting.
(2) Using an open end wrench, install and tighten
the A/C pressure transducer onto the fitting on the
liquid line between the filter-drier and the expansion
valve (Fig. 3).
(3) Reconnect the headlamp and dash wire harness
connector for the A/C pressure transducer to the
transducer connector receptacle.
(4) Reconnect the battery negative cable.
BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors (Fig. 4). Models
with the single zone heater and air conditioner sys-tem have a single blend air door, which is controlled
by a single blend door actuator. Models with the
optional dual zone front heater and air conditioner
system have dual blend air doors, which are con-
trolled by two blend door actuators. The single zone
blend door actuator is located on the driver side end
of the heater-A/C housing unit, close to the dash
panel. In the dual zone system, the same blend door
actuator used for the single zone system becomes the
passenger blend door actuator, and is mechanically
connected to only the passenger side blend air door.
In the dual zone system, a second separate blend
door actuator is also located on the driver side end of
the heater-A/C housing unit close to the instrument
panel, and is mechanically connected to only the
driver side blend air door.
The blend door actuators are interchangeable with
each other, as well as with the actuators for the
mode door and the recirculation air door. Each actua-
tor is contained within an identical black molded
plastic housing with an integral wire connector
receptacle. Two integral mounting tabs allow the
actuator to be secured with two screws to the heater-
A/C unit housing. Each actuator also has an identical
output shaft with splines that connects it to the link-
age that drives the proper blend air door. The blend
door actuators do not require mechanical indexing to
the blend door linkage, as they are electronically cal-
ibrated by the heater-A/C control module. The blend
door actuators cannot be adjusted or repaired and, if
damaged or faulty, they must be replaced.
Fig. 3 A/C Pressure Transducer
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
Fig. 4 Blend Door Actuator
1 - CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE-ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
RSCONTROLS - FRONT24-11
A/C PRESSURE TRANSDUCER (Continued)

(11) On models with the 3.3L and 3.8L engines
only, loosely install the three screws and one nut that
secure the compressor to the engine. Tighten each of
the fasteners using the following sequence to 54 N´m
(40 ft. lbs.).
²The upper screw at the rear of the compressor.
²The lower screw at the rear of the compressor.
²The lower screw at the front of the compressor.
²The upper nut at the front of the compressor.
(12) On models with the 3.3L and 3.8L engines
only, engage the retainer on the engine wire harness
compressor clutch coil take out with the bracket on
the top of the compressor.
(13) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(14) Reinstall the serpentine accessory drive belt
onto the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTAL-
LATION).
(15) Lower the vehicle.
(16) Reconnect the battery negative cable.
(17) If a new clutch plate and/or clutch pulley are
being installed, the new clutch components must be
burnished. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH - STANDARD PROCEDURE - COMPRES-
SOR CLUTCH BREAK-IN).
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL
The air conditioning compressor clutch coil electri-
cal circuit is controlled by the Powertrain Control
Module (PCM) through the compressor clutch relay,
which is located in the Intelligent Power Module
(IPM) in the engine compartment near the battery.
Begin testing of a suspected compressor clutch coil
problem by performing the preliminary checks.
PRELIMINARY CHECKS
(1) If the compressor clutch will not engage, verify
the refrigerant charge level. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - FRONT/RE-
FRIGERANT - DIAGNOSIS AND TESTING -
REFRIGERANT CHARGE LEVEL). If the refriger-
ant charge level is OK, go to Step 2. If the refriger-
ant charge level is not OK, adjust the refrigerant
charge as required.
(2) If the a/c compressor clutch still will not
engage, disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer andcheck for battery current at the connector with the
engine running and the heater-A/C control set to the
A/C mode. If OK, go to TESTS . If not OK, use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information.
TESTS
(1) Verify the battery state of charge. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY -
DIAGNOSIS AND TESTING).
(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the heater-A/C control in the A/C mode
and the blower at low speed, start the engine and
allow it to run at a normal idle speed.
(4) The compressor clutch should engage immedi-
ately, and the clutch coil voltage should be within
two volts of the battery voltage. If the coil voltage is
not within two volts of battery voltage, test the
clutch coil feed circuit for excessive voltage drop. If
the compressor clutch does not engage, use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information.
(5) With the ambient temperature at 21É C (70É F),
the compressor clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5 to 12.5 volts at the
clutch coil. If the voltage is more than 12.5 volts, add
electrical loads by turning on electrical accessories
until the voltage reads below 12.5 volts.
(a) If the compressor clutch coil current reading
is zero, the coil is open and must be replaced.
(b) If the compressor clutch coil current reading
is four amperes or more, the coil is shorted and
must be replaced.
COMPRESSOR CLUTCH RELAY
DESCRIPTION
The compressor clutch relay (Fig. 18) is a Interna-
tional Standards Organization (ISO) micro-relay.
Relays conforming to the ISO specifications have
common physical dimensions, current capacities, ter-
minal patterns, and terminal functions. The ISO
micro-relay terminal functions are the same as a con-
ventional ISO relay. However, the ISO micro-relay
terminal pattern (or footprint) is different, the cur-
rent capacity is lower, and the physical dimensions
are smaller than those of the conventional ISO relay.
The compressor clutch relay is located in the Intelli-
gent Power Module (IPM), which is in the engine
compartment near the battery. See the fuse and relay
layout map molded into the inner surface of the IPM
RSCONTROLS - FRONT24-21
COMPRESSOR CLUTCH (Continued)

HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
Remove all test equipment before returning the vehi-
cle to service.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer from
the transducer on the front liquid line rear section
(Fig. 14).(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the filter-drier.
(7) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.
(9) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve and move the lines
out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Disconnect the HVAC wire harness connector
for the evaporator temperature sensor from the sen-
sor on the top of the expansion valve.
(15) Remove the two screws that secure the expan-
sion valve to the evaporator tube tapping plate.
(16) Remove the expansion valve from the evapo-
rator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
(19) Remove the evaporator temperature sensor
from the expansion valve. (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS - FRONT/EVAPO-
RATOR TEMPERATURE SENSOR - REMOVAL).
INSTALLATION
(1) Reinstall the evaporator temperature sensor
onto the expansion valve (Fig. 14). (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/EVAPORATOR TEMPERATURE SENSOR -
INSTALLATION).
(2) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the expansion valve.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(4) Position the expansion valve onto the evapora-
tor inlet and outlet tube fittings.
(5) Install and tighten the two screws that secure
the expansion valve to the evaporator tube tapping
plate plate. Tighten the screws to 11 N´m (97 in.
lbs.).
(6) Reconnect the HVAC wire harness connector
for the evaporator temperature sensor to the sensor
Fig. 14 Expansion Valve
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - FRONT LIQUID LINE REAR SECTION
RSPLUMBING - FRONT24-75
EXPANSION VALVE (Continued)

connector receptacle on the top of the expansion
valve.
(7) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(9) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(10) Install and tighten the nut that secures the
suction line and liquid line fittings to the stud on the
expansion valve. Tighten the nut to 23 N´m (17 ft.
lbs.).
(11) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(13) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(14) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (18 in. lbs.).
(15) Reconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer to the
transducer on the front liquid line rear section.
(16) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(17) Reinstall the air cleaner housing into the
right side of the engine compartment.
(18) Reconnect the battery negative cable.
(19) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(20) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing of the heater-A/C unit, under the instrument
panel. It is a heat exchanger made of rows of tubes
and fins. One end of the core is fitted with a molded
plastic tank that includes integral heater core inlet
and outlet ports. The removable heater core tubes
are held in place these ports by a sealing plate
secured with a screw to the heater core tank. This
removable heater core tube arrangement allows theheater core to be serviced without removing the heat-
er-A/C unit housing from the vehicle. The heater core
cannot be repaired and, if faulty or damaged, it must
be replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the heater-A/C unit housing is directed through the
heater core.
REMOVAL- HEATER CORE EXTENSION TUBES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the heater hoses from the heater
hose tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
24 - 76 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)