oil capacity CHRYSLER VOYAGER 2001 User Guide

ND-8 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance. PAG
refrigerant oil is much more hygroscopic than min-
eral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil
container should always be kept tightly capped until
it is ready to be used. After use, recap the oil con-
tainer immediately to prevent moisture contamina-
tion.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
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).
When an air conditioning system is assembled at
the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The receiver/drier, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the
compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when an receiver/
drier, evaporator or condenser is replaced. See the
Refrigerant Oil Capacities chart for the proper
amount of refrigerant oil to add. When a compressoris replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of fresh new
refrigerant oil that was drained out of the old com-
pressor.
REFRIGERANT OIL CAPACITIES
Front A/C Front & Rear
A/C
COMPONENT ml fl oz ml fl oz
Compressor 150 5.0 220 7.4
Filter-Drier 30 1.0 30 1.0
Condenser 30 1.0 30 1.0
Front Evaporator 60 2.0 60 2.0
Rear Evap. (including
underbody lines)N/A N/A 60 2.0
Compressor Drain and measure the oil
from the old compressor -
See text above.
SUCTION LINE
REMOVAL
The front air conditioner suction line includes the
low side service port on a section of tubing located
near the compressor. On models equipped with the
optional rear air conditioner, the front air conditioner
suction line also includes a suction line hose and
tube extension that connects the front suction line to
the suction line for the rear air conditioner.
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 top cover and snorkel
from the air cleaner housing located on 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.
24 - 92 PLUMBING - FRONTRS
REFRIGERANT OIL (Continued)

(10) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting (Fig. 35).
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.
(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(20) Lower the vehicle.
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).UNDERBODY LINES
DESCRIPTION
The rear heater-A/C unit plumbing is used only on
models with the optional rear heater-A/C unit. The
formed metal rear heater-A/C unit suction line, liquid
line, and heater lines are available for separate ser-
vice replacement. The molded and straight heater
hoses used on the rear heater-A/C unit can be ser-
viced in the vehicle. Refer to Group 7 - Cooling Sys-
tem for the heater hose service procedures.
OPERATION
The rear heater and A/C lines are all serviced as
individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any
contaminations that can get in to the system (Fig. 9),
(Fig. 10), (Fig. 12), (Fig. 11) and (Fig. 13).
Any kinks or sharp bends in the rear heater-A/C
unit plumbing will reduce the capacity of the entire
heating and air conditioning system. Kinks and
sharp bends reduce the system flow. High pressures
are produced in the refrigerant system when the air
conditioning compressor is operating. High tempera-
ture coolant is present in the heater plumbing when
the engine is operating. Extreme care must be exer-
cised to make sure that each of the plumbing connec-
tions is pressure-tight and leak free.
Fig. 9 Rear Heater and A/C Lines
1 - HEATER CONNECTION
2 - REAR A/C LINE BLOCK CONNECTION
RSPLUMBING - REAR24 - 105
SUCTION LINE (Continued)

²Vehicle Speed Sensor
²Engine Coolant Temperature Sensor
²Throttle Position Sensor
²Engine Controller Self Test Faults
²Cam or Crank Sensor
²Injector and Coil
²Idle Air Control Motor
²EVAP Electrical
²EGR Solenoid Electrical
²Intake Air Temperature
²5 Volt Feed
ConflictÐThe Task Manager does not run the
Oxygen Sensor Monitor if any of the following condi-
tions are present:
²A/C ON (A/C clutch cycling temporarily sus-
pends monitor)
²Purge flow in progress
²Ethanel content learn is takeng place and the
ethenal used once flag is set
SuspendÐThe Task Manager suspends maturing
a fault for the Oxygen Sensor Monitor if an of the fol-
lowing are present:
²Oxygen Sensor Heater Monitor, Priority 1
²Misfire Monitor, Priority 2
OXYGEN SENSOR HEATER MONITOR
DESCRIPTIONÐIf there is an oxygen sensor
(O2S) DTC as well as a O2S heater DTC, the O2S
fault MUST be repaired first. After the O2S fault is
repaired, verify that the heater circuit is operating
correctly.
The voltage readings taken from the O2S are very
temperature sensitive. The readings are not accurate
below 300ÉC. Heating of the O2S is done to allow the
engine controller to shift to closed loop control as
soon as possible. The heating element used to heat
the O2S must be tested to ensure that it is heating
the sensor properly.
The heater element itself is not tested. The sensor
output is used to test the heater by isolating the
effect of the heater element on the O2S output volt-
age from the other effects. The resistance is normally
between 100 ohms and 4.5 megaohms. When oxygen
sensor temperature increases, the resistance in the
internal circuit decreases. The PCM sends a 5 volts
biased signal through the oxygen sensors to ground
this monitoring circuit. As the temperature increases,
resistance decreases and the PCM detects a lower
voltage at the reference signal. Inversely, as the tem-
perature decreases, the resistance increases and the
PCM detects a higher voltage at the reference signal.
The O2S circuit is monitored for a drop in voltage.
OPERATIONÐThe Oxygen Sensor Heater Moni-
tor begins after the ignition has been turned OFF
and the O2 sensors have cooled. The PCM sends a 5
volt bias to the oxygen sensor every 1.6 seconds. ThePCM keeps it biased for 35 ms each time. As the sen-
sor cools down, the resistance increases and the PCM
reads the increase in voltage. Once voltage has
increased to a predetermined amount, higher than
when the test started, the oxygen sensor is cool
enough to test heater operation.
When the oxygen sensor is cool enough, the PCM
energizes the ASD relay. Voltage to the O2 sensor
begins to increase the temperature. As the sensor
temperature increases, the internal resistance
decreases. The PCM continues biasing the 5 volt sig-
nal to the sensor. Each time the signal is biased, the
PCM reads a voltage decrease. When the PCM
detects a voltage decrease of a predetermined value
for several biased pulses, the test passes.
The heater elements are tested each time the
engine is turned OFF if all the enabling conditions
are met. If the monitor fails, the PCM stores a
maturing fault and a Freeze Frame is entered. If two
consecutive tests fail, a DTC is stored. Because the
ignition is OFF, the MIL is illuminated at the begin-
ning of the next key cycle.
Enabling ConditionsÐThe following conditions
must be met for the PCM to run the oxygen sensor
heater test:
²Engine run time of at least 5.1 minutes
²Key OFF power down
²Battery voltage of at least 10 volts
²Sufficient Oxygen Sensor cool down
Pending ConditionsÐThere are not conditions or
situations that prompt conflict or suspension of test-
ing. The oxygen sensor heater test is not run pending
resolution of MIL illumination due to oxygen sensor
failure.
SuspendÐThere are no conditions which exist for
suspending the Heater Monitor.
CATALYST MONITOR
To comply with clean air regulations, vehicles are
equipped with catalytic converters. These converters
reduce the emission of hydrocarbons, oxides of nitro-
gen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a
catalyst to decay. A meltdown of the ceramic core can
cause a reduction of the exhaust passage. This can
increase vehicle emissions and deteriorate engine
performance, driveability and fuel economy.
The catalyst monitor uses dual oxygen sensors
(O2S's) to monitor the efficiency of the converter. The
dual O2S strategy is based on the fact that as a cat-
alyst deteriorates, its oxygen storage capacity and its
efficiency are both reduced. By monitoring the oxy-
gen storage capacity of a catalyst, its efficiency can
be indirectly calculated. The upstream O2S is used to
detect the amount of oxygen in the exhaust gas
before the gas enters the catalytic converter. The
RSEMISSIONS CONTROL25-3
EMISSIONS CONTROL (Continued)

important to block the wheels on front-wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
applicable. These procedures can be found in ser-
vice manual procedures. Following these proce-
dures is very important to the safety of individuals
performing diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRB MULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS INJURY.
CAREFULLY READ AND UNDERSTAND THE
CAUTIONS AND THE SPECIFICATION
LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
²Do not use the DRB if it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
FUNCTION INPUT LIMIT
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a
10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the DRBIIIt
away from spark plug or coil wires to avoid mea-
suring error from outside interference.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIITSCREEN WHILE IN
MOTION. DO NOT HANG THE DRBIIITFROM
THE REAR VIEW MIRROR OR OPERATE IT
YOURSELF. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIT.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is off. Failure to do so could
damage the module.
11
GENERAL INFORMATION

information at the time of publication. The right is
reserved to make changes at any time without
notice.
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIMES AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Some operations in this manual require that
hydraulic tubes, hoses, and fittings, disconnected
for inspection or testing purposes. These systems,
when fully charged contains fluid at high pressure.
Before disconnecting any hydraulic tubes, hoses or
fittings, be sure that the system is fully depressur-
ized.
When servicing a vehicle, always wear eye pro-
tection and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a transmission system problem,
it is important to follow approved procedures where
applicable. Following these procedures is very im-
portant to the safety of individuals performing
diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur. It is extremely impor-
tant that accurate shift lever position data be avail-
able to the TCM. The accuracy of any diagnostic
trouble code found in memory is doubtful unless the
Shift Lever Test, performed on the DRBtScan Tool,
passes.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system subcompo-
nents may result in personal injury and/or im-
proper system operation. Only those components
with approved repair and installation procedures in
the service instructions should be serviced.
4.2.4 DRBIIITSAFETY INSTRUCTIONS
WARNING: EXCEEDING THE LIMITS OF THE
DRBTMULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS OR POSSIBLY
FATAL INJURY. CAREFULLY READ AND
UNDERSTAND THE CAUTIONS AND THE
SPECIFICATION LIMITS.
²Follow the vehicle manufacturer 's service speci-
fications at all times.
²Do not use the DRBtif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table.
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
*Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a
10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeds 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before attempting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the DRBt
away from spark plug or coil wires to avoid
measuring error from outside interference.
19
GENERAL INFORMATION