1996 CHRYSLER VOYAGER oil filter

VALVE BODY
REMOVAL
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise.
Fig. 26 Transaxle Control Module
Fig. 27 Remove Oil Pan Bolts
Fig. 28 Remove Oil Pan
Fig. 29 Remove Oil Filter
Fig. 30 Remove Valve Body Attaching Bolts
Fig. 31 Push Park Rod Rollers from Guide Bracket
21 - 88 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)

TRANSAXLE DISASSEMBLE
NOTE: Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
(1) Remove input and output speed sensors.
(2) Remove transaxle solenoid pack (Fig. 59).
Fig. 58 Low/Reverse Switch Valve And T/C Limit
Valve
Fig. 59 Remove Solenoid Pack
Fig. 60 Remove Oil Pan Bolts
Fig. 61 Remove Oil Pan
Fig. 62 Remove Oil Filter
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 95
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Do not handle the valve body from the
manual valve. Damage could result.
Fig. 277 Accumulator (Overdrive)
Fig. 278 Install Accumulators
Fig. 279 Install Valve Body
Fig. 280 Install Valve Body Attaching Bolts
Fig. 281 Install Oil Filter
Fig. 282 Install Oil Pan
21 - 138 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

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

unit housing. On air conditioned vehicles, the air
passes through the evaporator. At this point the air
flow can be directed either through or around the
heater core. This is done by adjusting the blend- air
door with the TEMP control on the control head. An
optional zone control HVAC control module is avail-
able. This unit has dual blend-air doors that can be
regulated independently of each other. The tempera-
ture setting can be different from driver's side to pas-
senger side. After the air passes the blend-air door(s),
the air flow can then be directed from the Panel,
Floor, and Defrost outlets. Air flow velocity can be
adjusted with the blower speed selector switch on the
control head.
Ambient air intake can be shut off by closing the
recirculating air door. This will recirculate the air
that is already inside the vehicle. This is done by
depressing the Recirc. button on the control head. On
air conditioned vehicles, moving the control to Mix or
Defrost depresses the A/C button and will engage the
compressor. This will send refrigerant through the
evaporator, and remove heat and humidity from the
air before it goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
capacity of the system and consequently result in
higher discharge air temperatures.NOTE: The oil used in the compressor is ND8 PAG
R134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial 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.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and
components. The evaporator, condenser, and filter-
drier will retain a significant amount of oil, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent is replaced, the specified amount of refrigerant
oil must be added. When the compressor is replaced,
the amount of oil that is retained in the rest of the
system must be drained from the replacement com-
pressor. When a line or component has ruptured and
oil has escaped, the compressor should be removed
and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the sys-
tem, minus the amount of oil still in the remaining
components, can be measured and poured into the
suction port of the compressor.
Example: On a dual system the evaporator retains
60 ml (2 oz). The condenser retains 30 ml (1 oz) of
oil, and system capacity may be 220 ml (7.40 oz) of
oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
Fig. 5 Demister Inlet
NSHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)

CAUTION: The refrigerant oil used in a R-134a A/C
system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil
designated for this vehicle is ND8 PAG (polyalka-
lene glycol).
SERVICING REFRIGERANT OIL LEVEL
(1) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(2) Remove refrigerant lines from A/C compressor.
(3) Remove compressor from vehicle.
(4) From suction port on top of compressor, drain
refrigerant oil from compressor.
(5) Add system capacity minus the capacity of
components that have not been replaced through suc-
tion port on compressor. Refer to the Refrigerant Oil
Capacity Chart.
(6) Install compressor, connect refrigerant lines,
evacuate, and charge refrigerant system.
DIAGNOSIS AND TESTING
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST
GENERAL INFORMATION
If the HVAC control module is replaced, the Cali-
bration Diagnostic and Cooldown tests will need to
be performed. Once this group of tests have success-
fully passed, they can be performed individually. The
engine must be running during the test to provide
hot coolant for the heater, A/C compressor operation
and to assure that the actuators are calibrated cor-
rectly. The HVAC control module is capable of trou-
bleshooting the system in approximately 120 seconds.
If a condition is detected, an error code is displayed.
The error code cannot be erased until the condition is
repaired and the diagnostic test is performed. Check
wire before replacing components, refer to Group 8W,
Wiring Diagrams.CAUTION: Do not remove the actuators from the
Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF.
The actuators have no mechanical stops to limit the
travel. If the actuator rotates and is not connected
to the unit assembly, it will become out of calibra-
tion.
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibra-
tion compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In-
vehicle calibration can be entered from the control's
front panel. If the REAR WIPE and INTERMIT-
TENT LED's flash simultaneously when Ignition is
cycled ON, the actuators have not been calibrated or
during the previous calibration a failure occurred
(Fig. 6) and (Fig. 7). Diagnostics will always occur
during Calibration Diagnostic and Cooldown test.
REFRIGERANT OIL CAPACITIES
Refrigerant
Oil Capaci-
tiesFront A/C Dual A/C
Component ml oz ml oz
Compressor 150 ml 5.0 oz 220 ml 7.4 oz
Filter-Drier 30 ml 1.0 oz 30 ml 1.0 oz
Condenser 30 ml 1.0 oz 30 ml 1.0 oz
Evaporator 60 ml 2.0 oz 60 ml 2 .0 oz
Rear Evap. N/A N/A 60 ml 2.0 oz
Fig. 6 Radio Bezel and HVAC Control
24 - 6 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)

COMPRESSOR
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE
PROCEDURES FOR INFORMATION REGARDING
PROPER RECOVERY OF THE REFRIGERANT
BEFORE ATTEMPTING TO REMOVE THE COM-
PRESSOR.
(1) Disconnect negative battery cable.
(2) Pinch off coolant lines to rear Heat unit (if
equipped). Drain engine coolant.
(3) Remove upper radiator hose.
(4) Remove drive belt (refer to Group 7, Cooling
System). Disconnect compressor clutch wire lead.
(5) Remove refrigerant lines from compressor (Fig.
21) and (Fig. 22).
(6) Remove compressor nuts and bolts (Fig. 23).
(7) Remove compressor (Fig. 24).
INSTALLATION
For installation, reverse the above procedures.
COMPRESSOR CLUTCH/COIL
REMOVAL
(1) Remove the compressor shaft bolt (Fig. 25). A
band type oil filter removal tool can be placed around
the clutch plate to aid in bolt removal.
Fig. 21 Suction Line
Fig. 22 Discharge line
Fig. 23 Compressor Mounts
Fig. 24 Compressor Removal
NSHEATING AND AIR CONDITIONING 24 - 23
REMOVAL AND INSTALLATION (Continued)

CAUTION: The clutch pulley and the front plate
were mated at the factory by a burnishing opera-
tion. No attempt should be made to separately
replace either part. This will result in clutch slip-
page due to insufficient contact area.
INSTALLATION
(1) Align pin in back of field coil with hole in com-
pressor end housing, and position field coil into place.
Make sure that lead wires are properly routed, and
fasten with the wire clip screw.
(2) Install field coil retaining snap ring with snap
ring pliers. The bevel side of the snap ring facing
outward. Also both snap ring eyelets must be to the
right or left of the pin on compressor. Press snap ring
to make sure it is properly seated in the groove.
CAUTION: If snap ring is not fully seated it will
vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
(3) Install pulley assembly to compressor. If neces-
sary, tap gently with a block of wood on the friction
surface (Fig. 29).
CAUTION: Do not mar the pulley frictional surface.
(4) Install pulley assembly retaining snap ring
(bevel side outward) with snap ring pliers. Press the
snap ring to make sure it is properly seated in the
groove.
(5) If the original front plate assembly and pulley
assembly are to be reused, the old shim(s) can beused. If not, place a trial stack of shims, 1 mm (0.040
in.) thick, on the shaft against the shoulder.
(6) Install front plate assembly onto shaft.
(7) With the front plate assembly tight against the
shim(s), measure the air gap between front plate and
pulley face with feeler gauges. The air gap should be
between 0.5 and 0.9 mm (.020 and .035 inch) If
proper air gap is not obtained, add or subtract shims
until desired air gap is obtained.
(8) Install compressor shaft bolt. Tighten to
17.562 N´m (155620 in. lbs.).
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After a new clutch has been installed, check the
voltage and amperage to the clutch (determine it to
be satisfactory). Then cycle the A/C clutch approxi-
mately 20 times (5 sec. on and 5 sec. off). For this
procedure, set the system to the A/C mode, using
high blower, and engine rpm at 1500-2000. This pro-
cedure (burnishing) will seat the opposing friction
surfaces and provide a higher clutch torque capabil-
ity.
CONDENSER ASSEMBLY
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
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.
REMOVAL
(1) Recover A/C system refrigerant.
(2) Remove liquid line at filter-drier (Fig. 30).
(3) Remove (2) bolts attaching filter-drier to radia-
tor module (Fig. 31).
(4) Remove upper radiator crossmember.
(5) Tilt radiator rearward.
(6) Remove upper discharge line at condenser (Fig.
32).
(7) Through fascia, remove lower liquid line from
filter-drier.
(8) Remove (2) lower condenser mounting bolts.
(9) Remove (2) upper mounting bolts.
(10) Remove condenser from vehicle (Fig. 33).
Fig. 29 Installing Pulley Assembly
NSHEATING AND AIR CONDITIONING 24 - 25
REMOVAL AND INSTALLATION (Continued)