Rear system CHRYSLER VOYAGER 2005 Service Manual

(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
er-A/C system (Fig. 8).
(18) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(19) Remove the O-ring seal from the underbody
liquid line fitting and discard.
(20) Install plugs in, or tape over the opened liquid
line fittings.
(21) Lower the vehicle.
(22) Remove the liquid line from the engine com-
partment.
INSTALLATION
(1) Position the rear section of the front liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the receiver/drier and the
receiver/drier outlet port.(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the receiver/
drier outlet port on the top of the receiver/drier.
(9) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(10) If equipped, reinstall the A/C ground strap
eyelet terminal connector onto the weld stud on the
top of the right front strut tower (if equipped).
(11) If equipped, install the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.)
(12) Install the A/C pressure transducer (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
A/C PRESSURE TRANSDUCER - INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(18) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings 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-
A/C system.
(20) Lower the vehicle.
(21) Reconnect the battery negative cable.
(22) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
SUCTION LINE
REMOVAL
On models equipped with the optional rear A/C
system, the front air conditioner suction line also
includes a suction line hose and tube extension that
connects the front suction line to the underbody suc-
tion line for the rear A/C system.
Fig. 8 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
24 - 106 PLUMBING - REARRS
LIQUID LINE (Continued)

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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD 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.
(5) Remove the nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment (Fig. 9).
(10) Remove the nut that secures the suction line
and liquid line fittings to the front expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the front expansion valve.
(12) Remove the O-ring 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) Raise and support the vehicle.
(15) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 10).
(16) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.
(17) Remove the O-ring seal from the underbody
suction line fitting and discard.
(18) Install plugs in, or tape over the opened suc-
tion line fittings.
(19) Lower the vehicle.
(20) Remove the suction line from the engine com-
partment.
INSTALLATION
(1) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
Fig. 9 Suction Line
1 - A/C EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - RETAINING CLIP
5 - SUCTION LINE
Fig. 10 Underbody Line Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
RSPLUMBING - REAR24 - 107
SUCTION LINE (Continued)

(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the front expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Reconnect the suction line fitting to the com-
pressor suction port.
(10) Install the nut that secures the suction line
fitting to the A/C 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) Raise and support the vehicle.
(15) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(16) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.(17) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fitting
to 23 N´m (17 ft. lbs.).
(18) 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.
(19) Lower the vehicle.
(20) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(21) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
The underbody heater-A/C plumbing is used only
on models with the optional rear heater-A/C system
(Fig. 11). The underbody suction line, liquid line, and
heater tubes can each be serviced separately.
OPERATION
The rear heater and A/C lines are all serviced as
individual components. When disconnecting any lines
or connections, make sure that the area around the
line or connection is clean of any dirt or residue that
may enter and contaminate the rear heating-A/C sys-
tem (Fig. 12) and (Fig. 13).
Fig. 11 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
24 - 108 PLUMBING - REARRS
SUCTION LINE (Continued)

WARNING: HIGH PRESSURES ARE PRODUCED IN
THE REFRIGERANT SYSTEM WHEN THE A/C COM-
PRESSOR IS OPERATING. HIGH TEMPERATURE
COOLANT IS PRESENT IN THE HEATER PLUMBING
WHEN THE ENGINE IS OPERATING. EXTREME
CARE MUST BE EXERCISED WHEN SERVICING
THE REAR HEATER AND A/C LINES TO PREVENT
POSSIBLE PERSONAL INJURY.
Any kinks or sharp bends in the rear heater-A/C
plumbing will reduce the capacity of the entire heat-
ing-A/C system. Kinks and sharp bends reduce the
system flow. High pressures are produced in the
refrigerant system when the A/C compressor is oper-
ating. High temperature coolant is present in the
heater plumbing when the engine is operating.
Extreme care must be exercised to make sure that
each of the connections is pressure-tight and leak
free.
REMOVAL
UNDERBODY HEATER 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 -
WARNING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).(2) Raise and support vehicle.
(3) Disconnect the underbody heater tubes at the
rear of the vehicle by releasing the insert in the
underbody heater tube quick connect fittings and
carefully pulling downward on the heater tube fit-
tings (Fig. 14).
(4) Lower the underbody heater tubes and drain
any residual coolant from the tubes into a suitable
container.
Fig. 12 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
Fig. 13 Front Extension Lines to Underbody Lines ±
Typical
RSPLUMBING - REAR24 - 109
UNDERBODY LINES (Continued)

(5) Using spring tension clamp pliers, compress
and slide the clamps off of the rubber hoses at the
front of the underbody heater tubes (Fig. 15).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(6) Disconnect the heater hoses by carefully twist-
ing the hoses back and forth on the rear heater
extension tubes, while gently pulling them away
from the end of the tubes.
(7) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
(8) Remove the screws that secure the underbody
line retaining straps to the vehicle underbody.
(9) Remove the underbody heater tubes from the
retaining straps.
(10) Remove the underbody heater tubes from the
vehicle.
UNDERBODY REFRIGERANT LINES
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 CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT RECOVERY).
(2) Raise and support vehicle.
(3) Disconnect the exhaust system from the
exhaust hanger rubber isolators and position the
exhaust system out of the way (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(4) Disconnect the underbody refrigerant lines
from the front liquid and suction line extension tubes
and remove and discard the O-ring seals. (Fig. 16).
Fig. 15 Underbody Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 16 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 14 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
24 - 110 PLUMBING - REARRS
UNDERBODY LINES (Continued)

INSTALLATION
UNDERBODY HEATER TUBES
(1) Position the underbody heater tubes onto the
vehicle underbody.
(2) Install the underbody heater tubes into the
underbody line retaining straps.
(3) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.
(4) Connect the rubber hoses at the front of the
underbody heater tubes to the rear heater extension
tubes.
(5) Using spring tension clamp pliers, compress
and slide the clamps that secure the heater hoses
over the extension tubes. Release the clamp when it
is correctly positioned over the tube.
(6) Connect the rear underbody heater tube quick
connections to the rear heater core extension tubes.
(7) Lower the vehicle.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
UNDERBODY REFRIGERANT LINES
(1) If removed, install the underbody refigerant
lines into the underbody refrigerant line sealing plate
and install the nylon wedges that secure the refrig-
erant lines to the sealing plate.
(2) Position the underbody refrigerant lines onto
the vehicle underbody.
(3) Install the underbody refrigerant lines into the
underbody line retaining straps.
(4) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.(5) Remove the tape or plugs from the rear under-
body refrigerant line fittings and the rear evaporator
extension line ports.
(6) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(7) Connect the underbody refrigerant lines to the
rear evaporator extension line tapping plate.
(8) Install the bolt or nut (depending on applica-
tion) that secures the underbody refrigerant line
sealing plate to the rear evaporator extension line
tapping plate. Tighten the bolt or nut to 23 N´m (17
ft. lbs.).
(9) Remove the tape or plugs from the front liquid
and suction line extension tubes and the underbody
refrigerant line fittings.
(10) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(11) Connect the underbody refrigerant line fit-
tings to the front liquid and suction line extension
tubes. Tighten the fittings to 23 N´m (17 ft. lbs.).
(12) Position the exhaust system and install it to
the exhaust hanger rubber isolators (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(13) Lower the vehicle.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
24 - 112 PLUMBING - REARRS
UNDERBODY LINES (Continued)

To monitor the system, the number of lean-to-rich
switches of upstream and downstream O2S's is
counted. The ratio of downstream switches to
upstream switches is used to determine whether the
catalyst is operating properly. An effective catalyst
will have fewer downstream switches than it has
upstream switches i.e., a ratio closer to zero. For a
totally ineffective catalyst, this ratio will be one-to-
one, indicating that no oxidation occurs in the device.
The system must be monitored so that when cata-
lyst efficiency deteriorates and exhaust emissions
increase to over the legal limit, the MIL (check
engine lamp) will be illuminated.
Monitor OperationÐTo monitor catalyst effi-
ciency, the PCM expands the rich and lean switch
points of the heated oxygen sensor. With extended
switch points, the air/fuel mixture runs richer and
leaner to overburden the catalytic converter. Once
the test is started, the air/fuel mixture runs rich and
lean and the O2 switches are counted. A switch is
counted when an oxygen sensor signal goes from
below the lean threshold to above the rich threshold.
The number of Rear O2 sensor switches is divided by
the number of Front O2 sensor switches to determine
the switching ratio.
The test runs for 20 seconds. As catalyst efficiency
deteriorated over the life of the vehicle, the switch
rate at the downstream sensor approaches that of the
upstream sensor. If at any point during the test
period the switch ratio reaches a predetermined
value, a counter is incremented by one. The monitor
is enabled to run another test during that trip. When
the test fails three times, the counter increments to
three, a malfunction is entered, and a Freeze Frame
is stored. When the counter increments to three dur-
ing the next trip, the code is matured and the MIL is
illuminated. If the test passes the first, no further
testing is conducted during that trip.
The MIL is extinguished after three consecutive
good trips. The good trip criteria for the catalyst
monitor is more stringent than the failure criteria. In
order to pass the test and increment one good trip,
the downstream sensor switch rate must be less than
80% of the upstream rate (60% for manual transmis-
sions). The failure percentages are 90% and 70%
respectively.
Enabling ConditionsÐThe following conditions
must typically be met before the PCM runs the cat-
alyst monitor. Specific times for each parameter may
be different from engine to engine.
²Accumulated drive time
²Enable time
²Ambient air temperature
²Barometric pressure
²Catalyst warm-up counter
²Engine coolant temperature²Accumulated throttle position sensor
²Vehicle speed
²MAP
²RPM
²Engine in closed loop
²Fuel level
Pending ConditionsÐ
²Misfire DTC
²Front Oxygen Sensor Response
²Front Oxygen Sensor Heater Monitor
²Front Oxygen Sensor Electrical
²Rear Oxygen Sensor Rationality (middle check)
²Rear Oxygen Sensor Heater Monitor
²Rear Oxygen Sensor Electrical
²Fuel System Monitor
²All TPS faults
²All MAP faults
²All ECT sensor faults
²Purge flow solenoid functionality
²Purge flow solenoid electrical
²All PCM self test faults
²All CMP and CKP sensor faults
²All injector and ignition electrical faults
²Idle Air Control (IAC) motor functionality
²Vehicle Speed Sensor
²Brake switch
²Intake air temperature
ConflictÐThe catalyst monitor does not run if any
of the following are conditions are present:
²EGR Monitor in progress
²Fuel system rich intrusive test in progress
²EVAP Monitor in progress
²Time since start is less than 60 seconds
²Low fuel level
²Low ambient air temperature
²Ethanel content learn is taking place and the
ethenal used once flag is set
SuspendÐThe Task Manager does not mature a
catalyst fault if any of the following are present:
²Oxygen Sensor Monitor, Priority 1
²Upstream Oxygen Sensor Heater, Priority 1
²EGR Monitor, Priority 1
²EVAP Monitor, Priority 1
²Fuel System Monitor, Priority 2
²Misfire Monitor, Priority 2
NON-MONITORED CIRCUITS
The PCM does not monitor all circuits, systems
and conditions that could have malfunctions causing
driveability problems. However, problems with these
systems may cause the PCM to store diagnostic trou-
ble codes for other systems or components. For exam-
ple, a fuel pressure problem will not register a fault
directly, but could cause a rich/lean condition or mis-
fire. This could cause the PCM to store an oxygen
sensor or misfire diagnostic trouble code.
RSEMISSIONS CONTROL25-5
EMISSIONS CONTROL (Continued)

EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
OPERATION - EVAPORATION CONTROL
SYSTEM............................11
SPECIFICATIONS
TORQUE............................12
EVAP/PURGE SOLENOID
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
FUEL FILLER CAP
DESCRIPTION.........................13
OPERATION...........................13
NATURAL VAC LEAK DETECTION ASSY
REMOVAL.............................14
INSTALLATION.........................14
LEAK DETECTION PUMP
REMOVAL.............................15
INSTALLATION.........................15
ORVR
OPERATION...........................15DIAGNOSIS AND TESTING - VEHICLE DOES
NOT FILL............................17
P C V VA LV E
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - PCV SYSTEM . . . 18
VAPOR CANISTER
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL
REMOVAL...........................19
REMOVAL - WITH NVLD - FOLD-IN-FLOOR . 20
REMOVAL - REAR EVAP CANISTER.......20
INSTALLATION
INSTALLATION.......................20
INSTALLATION - WITH NVLD - FOLD-IN-
FLOOR.............................20
INSTALLATION - REAR EVAP CANISTER . . . 21
EVAPORATIVE EMISSIONS
OPERATION - EVAPORATION CONTROL
SYSTEM
The evaporation control system prevents the emis-
sion of fuel tank vapors into the atmosphere. When
fuel evaporates in the fuel tank, the vapors pass
through vent hoses or tubes to an activated carbon
filled evaporative canister. The canister temporarily
holds the vapors. The Powertrain Control Module
(PCM) allows intake manifold vacuum to draw
vapors into the combustion chambers during certain
operating conditions (Fig. 1).All engines use a proportional purge solenoid sys-
tem. The PCM controls vapor flow by operating the
purge solenoid. Refer to Proportional Purge Solenoid
in this section.
NOTE: The evaporative system uses specially man-
ufactured hoses. If they need replacement, only use
fuel resistant hose. Also the hoses must be able to
pass an Ozone compliance test.
NOTE: For more information on Onboard Refueling
Vapor Recovery (ORVR), refer to the Fuel Delivery
section.
RSEVAPORATIVE EMISSIONS25-11

(2) Install hose on PCV valve. Remove the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) After allowing approximately one minute for
crankcase pressure to reduce, the paper should draw
up against the hose with noticeable force. If the
engine does not draw the paper against the grommet
after installing a new valve, replace the PCV valve
hose.
(4) Turn the engine off. Remove the PCV valve
from intake manifold. The valve should rattle when
shaken.
(5) Replace the PCV valve and retest the system if
it does not operate as described in the preceding
tests.Do not attempt to clean the old PCV valve.
If the valve rattles, apply a light coating of Loctitet
Pipe Sealant With Teflon to the threads. Thread the
PCV valve into the manifold plenum and tighten to 7
N´m (60 in. lbs.) torque.
VAPOR CANISTER
DESCRIPTION
There are 2 EVAP canisters on the vehicle. The
vacuum and vapor tubes connect to the top of the
canister. It is a charcoal canister (Fig. 15) or (Fig.
16).OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
ister. The canister temporarily holds the fuel vapors
until intake manifold vacuum draws them into the
combustion chamber. The Powertrain Control Module
(PCM) purges the canister through the proportional
purge solenoid. The PCM purges the canister at pre-
determined intervals and engine conditions.
Purge Free Cells
Purge-free memory cells are used to identify the
fuel vapor content of the evaporative canister. Since
the evaporative canister is not purged 100% of the
time, the PCM stores information about the evapora-
tive canister's vapor content in a memory cell.
The purge-free cells are constructed similar to cer-
tain purge-normal cells. The purge-free cells can be
monitored by the DRB IIItScan Tool. The only dif-
ference between the purge-free cells and normal
adaptive cells is that in purge-free, the purge is com-
pletely turned off. This gives the PCM the ability to
compare purge and purge-free operation.
REMOVAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the 2 hoses (Fig. 15).
(3) Remove bolt.
(4) Pull canister rearward to remove.
Fig. 15 FRONT EVAP CANISTER
1 - Front EVAP Canister
2 - Vent Valve
Fig. 16 REAR EVAP CANISTER
1 - Rear EVAP Canister
2 - Front EVAP Canister
3 - Vent Valve
RSEVAPORATIVE EMISSIONS25-19
PCV VALVE (Continued)

INDEX
ABS FASTENER TORQUE,SPECIFICATIONS ...................... 5-91
ABSORBER - DESCRIPTION, SHOCK .......2-36
ABSORBER - INSTALLATION, SHOCK ......2-38
ABSORBER - OPERATION, SHOCK ........2-36
ABSORBER - REMOVAL, SHOCK ..........2-36
ABSORBER (UPPER BUSHING) - ASSEMBLY, SHOCK .................... 2-37
ABSORBER (UPPER BUSHING) - DISASSEMBLY, SHOCK .................2-37
A/C CLUTCH BREAK-IN, STANDARD PROCEDURE ........................ 24-15
A/C COMPRESSOR CLUTCH COIL, DIAGNOSIS AND TESTING .............24-14
A/C COMPRESSOR CLUTCH RELAY - DESCRIPTION ....................... 24-18
A/C COMPRESSOR CLUTCH RELAY - INSTALLATION ....................... 24-19
A/C COMPRESSOR CLUTCH RELAY - OPERATION ......................... 24-18
A/C COMPRESSOR CLUTCH RELAY - REMOVAL .......................... 24-19
A/C COMPRESSOR CLUTCH/COIL - DESCRIPTION ....................... 24-13
A/C COMPRESSOR CLUTCH/COIL - OPERATION ......................... 24-13
A/C COMPRESSOR, DESCRIPTION .......24-72
A/C COMPRESSOR, INSTALLATION .......24-74
A/C COMPRESSOR MOUNTING BRACKET, 2.4L ENGINE ...........24-74,24-75
A/C COMPRESSOR NOISE DIAGNOSIS, DIAGNOSIS AND TESTING .............24-72
A/C COMPRESSOR, OPERATION .........24-72
A/C COMPRESSOR, REMOVAL ..........24-73
A/C CONDENSER - DESCRIPTION ........24-75
A/C CONDENSER - OPERATION ..........24-75
A/C COOL DOWN TEST, DIAGNOSIS AND TESTING ............................ 24-6
A/C DISCHARGE LINE - INSTALLATION . . . 24-80
A/C DISCHARGE LINE - REMOVAL .......24-79
A/C EVAPORATOR - DESCRIPTION . . 24-80,24-98
A/C EVAPORATOR - INSTALLATION ......24-81
A/C EVAPORATOR - OPERATION ....24-80,24-98
A/C EVAPORATOR - REMOVAL ..........24-81
A/C EVAPORATOR, INSTALLATION - REAR ............................. 24-100
A/C EVAPORATOR LINE EXTENSION, INSTALLATION - REAR ...............24-100
A/C EVAPORATOR LINE EXTENSION, REMOVAL - REAR .................... 24-99
A/C EVAPORATOR, REMOVAL - REAR .....24-98
A/C EXPANSION VALVE - DESCRIPTION . . 24-100
A/C EXPANSION VALVE - OPERATION ....24-100
A/C EXPANSION VALVE, DIAGNOSIS AND TESTING - FRONT .................... 24-82
A/C EXPANSION VALVE, DIAGNOSIS AND TESTING - REAR .................... 24-101
A/C HEATER CONTROL - DESCRIPTION . . . 24-19
A/C PERFORMANCE TEST, DIAGNOSIS AND TESTING ........................ 24-7
A/C PRESSURE TRANSDUCER - DESCRIPTION ....................... 24-20
A/C PRESSURE TRANSDUCER - OPERATION ......................... 24-20
A/C PRESSURE TRANSDUCER, DIAGNOSIS AND TESTING .............24-21
A/C SYSTEM - CAUTION ...............24-66
A/C SYSTEM, SPECIFICATIONS ..........24-11
A/C SYSTEM, WARNING ...............24-66
ACCELERATOR PEDAL - INSTALLATION . . . 14-28
ACCELERATOR PEDAL - REMOVAL .......14-28
ACCESSORY DRIVE BELT - DIAGNOSIS AND TESTING .........................7-7
ACCESSORY DRIVE BELT TENSION, SPECIFICATIONS .......................7-5
ACCUMULATOR - DESCRIPTION . . . 21-218,21-73
ACCUMULATOR - OPERATION ....21-218,21-73
A/C-HEATER CONTROL - DESCRIPTION . . . 24-33
A/C-HEATER CONTROL - INSTALLATION . . . 24-34
A/C-HEATER CONTROL - OPERATION .....24-33
A/C-HEATER CONTROL - REMOVAL ......24-33
A/C-HEATER CONTROL CALIBRATION, STANDARD PROCEDURE ...............24-19
ACTUATOR - DESCRIPTION, BLEND DOOR ........................ 24-22,24-34
ACTUATOR - DESCRIPTION, ENGAGE ......8N-9
ACTUATOR - DESCRIPTION, LATCH ......8N-13 ACTUATOR - DESCRIPTION, MODE
DOOR ............................. 24-29
ACTUATOR - DESCRIPTION, RECIRCULATION DOOR ................24-31
ACTUATOR - INSTALLATION, BLEND DOOR ........................ 24-22,24-35
ACTUATOR - INSTALLATION, ENGAGE ....8N-10
ACTUATOR - INSTALLATION, INSIDE HANDLE ............................ 23-27
ACTUATOR - INSTALLATION, LATCH .....8N-14
ACTUATOR - INSTALLATION, MODE DOOR ............................. 24-30
ACTUATOR - INSTALLATION, RECIRCULATION DOOR ................24-32
ACTUATOR - OPERATION, BLEND DOOR . . 24-22, 24-35
ACTUATOR - OPERATION, ENGAGE .......8N-9
ACTUATOR - OPERATION, LATCH ........8N-13
ACTUATOR - OPERATION, MODE DOOR . . . 24-29
ACTUATOR - OPERATION, RECIRCULATION DOOR ................24-31
ACTUATOR - REAR - DESCRIPTION, MODE DOOR ........................ 24-39
ACTUATOR - REAR - INSTALLATION, MODE DOOR ........................ 24-40
ACTUATOR - REAR - OPERATION, MODE DOOR ............................. 24-39
ACTUATOR - REAR - REMOVAL, MODE DOOR ............................. 24-39
ACTUATOR - REMOVAL, BLEND DOOR . . . 24-22, 24-35
ACTUATOR - REMOVAL, ENGAGE ..........8N-9
ACTUATOR - REMOVAL, INSIDE HANDLE . . 23-27
ACTUATOR - REMOVAL, LATCH .........8N-13
ACTUATOR - REMOVAL, MODE DOOR ....24-29
ACTUATOR - REMOVAL, RECIRCULATION DOOR ............................. 24-32
ADAPTER - INSTALLATION, FRONT DISC BRAKE CALIPER ...................... 5-31
ADAPTER - INSTALLATION, OIL FILTER . . . 9-142
ADAPTER - REMOVAL, FRONT DISC BRAKE CALIPER ...................... 5-31
ADAPTER - REMOVAL, OIL FILTER .......9-142
ADAPTIVE MEMORIES, OPERATION - FUEL CORRECTION OR ................14-24
ADDING ADDITIONAL COOLANT - STANDARD PROCEDURE .................7-4
ADDITIONAL COOLANT - STANDARD PROCEDURE, ADDING ...................7-4
ADHESIVE ATTACHED - INSTALLATION, EXTERIOR NAME PLATES ..............23-51
ADHESIVE ATTACHED - REMOVAL, EXTERIOR NAME PLATES ..............23-51
ADHESIVE LOCATIONS - FOLD-IN-FLOOR ONLY - SPECIFICATIONS,
STRUCTURAL ...................... 23-228
ADHESIVE LOCATIONS - SPECIFICATIONS, STRUCTURAL ........23-218
ADJUSTABLE - INSTALLATION, PEDALS ....5-43
ADJUSTABLE - REMOVAL, PEDALS .......5-40
ADJUSTABLE PEDALS SWITCH - INSTALLATION ........................ 5-11
ADJUSTABLE PEDALS SWITCH - REMOVAL ........................... 5-11
ADJUSTE R-BOR C-PILLAR -
INSTALLATION, SEAT BELT HEIGHT ......8O-38
ADJUSTE R-BOR C-PILLAR -
REMOVAL, SEAT BELT HEIGHT ..........8O-38
ADJUSTER - DIAGNOSIS AND TESTING, DRUM BRAKE AUTOMATIC ..............5-14
ADJUSTER - INSTALLATION, FRONT SEAT TRACK MANUAL ...............23-126
ADJUSTER - INSTALLATION, FRONT SEAT TRACK POWER ................23-124
ADJUSTER - REMOVAL, FRONT SEAT TRACK MANUAL .................... 23-125
ADJUSTER - REMOVAL, FRONT SEAT TRACK POWER ..................... 23-124
ADJUSTER KNOB - INSTALLATION, SEAT BELT HEIGHT ....................... 8O-38
ADJUSTER KNOB - REMOVAL, SEAT BELT HEIGHT ....................... 8O-38
ADJUSTER NOISE DIAGNOSIS - DIAGNOSIS AND TESTING, HYDRAULIC
LASH ............................... 9-34
ADJUSTER TENSION RELEASE - STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC .................... 5-63ADJUSTER TENSION RESET -
STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC .................... 5-64
ADJUSTER/MANUAL - OCS - INSTALLATION, FRONT SEAT TRACK ....23-128
ADJUSTER/MANUAL - OCS - REMOVAL, FRONT SEAT TRACK .................23-126
ADJUSTER/POWER - OCS - INSTALLATION, FRONT SEAT TRACK ....23-125
ADJUSTER/POWER - OCS - REMOVAL, FRONT SEAT TRACK .................23-124
ADJUSTERS - INSTALLATION, HYDRAULIC LASH ..................... 9-35
ADJUSTERS - REMOVAL, HYDRAULIC LASH ............................... 9-35
AERATION - DIAGNOSIS AND TESTING, COOLING SYSTEM .....................7-4
AFTER AN AIRBAG DEPLOYMENT - STANDARD PROCEDURE, SERVICE .......8O-7
AIR CLEANER ELEMENT - INSTALLATION . 9-101, 9-24
AIR CLEANER ELEMENT - REMOVAL . 9-101,9-24
AIR CLEANER HOUSING - INSTALLATION . 9-102, 9-25
AIR CLEANER HOUSING - REMOVAL . 9-101,9-25
AIR CONDITIONER, DESCRIPTION - HEATER ............................. 24-1
AIR CONDITIONER, OPERATION - HEATER ............................. 24-4
AIR CONTROL MOTOR - DESCRIPTION, IDLE ............................... 14-33
AIR CONTROL MOTOR - INSTALLATION, IDLE ............................... 14-33
AIR CONTROL MOTOR - OPERATION, IDLE ............................... 14-33
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-33
AIR EXHAUSTER - DESCRIPTION, REAR QUARTER PANEL/FENDER ..............23-59
AIR EXHAUSTER - INSTALLATION, REAR QUARTER PANEL/FENDER ..............23-60
AIR EXHAUSTER - REMOVAL, REAR QUARTER PANEL/FENDER ..............23-59
AIR FILTER - DESCRIPTION ............24-42
AIR FILTER - INSTALLATION ............24-43
AIR FILTER - REMOVAL ...............24-42
AIR GAP, SPECIFICATIONS - WHEEL SPEED SENSOR ....................... 5-91
AIR INTAKE PIPE - INSTALLATION ......24-115
AIR INTAKE PIPE - REMOVAL ..........24-115
AIR OUTLETS - DESCRIPTION .....24-43,24-56
AIR OUTLETS - INSTALLATION ..........24-56
AIR OUTLETS - REMOVAL .............24-56
AIR PRESSURE TESTS - DIAGNOSIS AND TESTING, CLUTCH ...........21-153,21-8
AIR TEMPERATURE SENSOR - DESCRIPTION, INLET .................14-34
AIRBAG - DESCRIPTION, CURTAIN .......8O-12
AIRBAG - DESCRIPTION, DRIVER ........8O-16
AIRBAG - DESCRIPTION, KNEE BLOCKER . 8O-22
AIRBAG - DESCRIPTION, PASSENGER ....8O-30
AIRBAG - INSTALLATION, CURTAIN ......8O-16
AIRBAG - INSTALLATION, DRIVER .......8O-18
AIRBAG - INSTALLATION, KNEE BLOCKER .......................... 8O-23
AIRBAG - INSTALLATION, PASSENGER . . . 8O-32
AIRBAG - OPERATION, CURTAIN ........8O-13
AIRBAG - OPERATION, DRIVER .........8O-16
AIRBAG - OPERATION, KNEE BLOCKER . . . 8O-22
AIRBAG - OPERATION, PASSENGER ......8O-30
AIRBAG - REMOVAL, CURTAIN ..........8O-14
AIRBAG - REMOVAL, DRIVER ...........8O-17
AIRBAG - REMOVAL, KNEE BLOCKER ....8O-23
AIRBAG - REMOVAL, PASSENGER .......8O-30
AIRBAG DEPLOYMENT - STANDARD PROCEDURE, SERVICE AFTER AN ........8O-7
AIRBAG DISABLED INDICATOR - DESCRIPTION, PASSENGER ............8O-33
AIRBAG DISABLED INDICATOR - INSTALLATION, PASSENGER ...........8O-34
AIRBAG DISABLED INDICATOR - OPERATION, PASSENGER ..............8O-33
AIRBAG DISABLED INDICATOR - REMOVAL, PASSENGER ...............8O-34
AIRBAG SYSTEM - DIAGNOSIS AND TESTING ............................ 8O-6
AIRBAGS - STANDARD PROCEDURE, HANDLING .......................... 8O-6
RS INDEX1
Description Group-Page Description Group-Page Description Group-Page