1996 CHRYSLER VOYAGER ECU

INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder.
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place
(Fig. 21).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install water shield and door trim panel.
FRONT DOOR OUTER BELT MOLDING
REMOVAL
(1) Remove door trim panel.
(2) Roll door glass down.
(3) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
22).
(4) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove front door trim panel and water shield
as necessary to gain access to the outside door han-
dle.
(2) Roll door glass up.(3) Through access hole at rear of inner door
panel, disconnect vehicle theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push-in fasteners holding VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch.
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel (Fig. 23).
(10) Remove outside door handle from vehicle.
Fig. 21 Install Front Door Lock Cylinder
Fig. 22 Front Door Outer Belt Molding
Fig. 23 Front Door Outside Handle
NSBODY 23 - 33
REMOVAL AND INSTALLATION (Continued)

to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 45).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(5) Install hood.
(6) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 46).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 47).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net-
pierced tabs. If alignment is required, flatten tabs.
(5) Install bolts attaching hood latch to radiator
closure panel crossmember.
(6) Verify hood operation and alignment. Adjust as
necessary.
Fig. 44 HoodFig. 45 Hood Hinge
Fig. 46 Hood Latch
NSBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)

EXPANSION VALVE
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Recover A/C system refrigerant.
(3) Remove the accessory drive belt.
(4) Remove upper generator bracket.
(5) Disconnect generator field wire connector.
(6) Push generator forward.
(7) Remove ground wire at dash panel.
(8) Remove the nut retaining the refrigerant line
sealing plate to the expansion valve (Fig. 39).
(9) Remove the stud from the expansion valve (Fig.
40).
(10) Carefully pull the refrigerant line sealing
plate assembly from expansion valve towards the
front of the vehicle. Use care not to scratch the
expansion valve sealing surfaces with pilot tubes.
(11) Cover the openings to prevent contamination.
(12) Remove two screws securing the expansion
valve to the evaporator sealing plate (Fig. 40).
(13) Carefully remove expansion valve (Fig. 41).
(14) Remove the old O-rings.
INSTALLATION
(1) Ensure old O-rings are removed. Install new
O-rings on the refrigerant lines and evaporator seal-
ing plate.
(2) Hand-start the stud into the expansion valve
and torque to7-11N´m(64-96in.lbs.).
(3) Carefully install the expansion valve to the
sealing plate. Install the two screws and tighten 8 to
14 N´m (70 to 130 in. lbs.) torque.(4) Carefully install the refrigerant lines and seal-
ing plate to the expansion valve. Install the nut and
tighten 20 to 26 N´m (170 to 230 in. lbs.) torque.
(5) Install the ground wire at dash panel.
(6) Pull generator back into the proper position for
bracket mounting.
(7) Install generator field wire connector.
(8) Install the upper generator bracket.
(9) Install accessory drive belt.
(10) Evacuate and recharge system.
(11) After expansion valve is installed, the system
is charged, and leaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Recover A/C system refrigerant.
Fig. 39 A/C Refrigerant Line Plate
Fig. 40 Expansion Valve Stud and Mounting Screws
Fig. 41 Expansion Valve Removal
24 - 28 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

(10) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(11) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 46).
(12) Disconnect the HVAC housing wiring harness.
(13) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
47).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 48).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 49)
(7) Pinch off heater lines under the hood.
(8) Remove heater core cover. Insert a small
amount of towels under the heater core tubes.
Remove heater core plate and tubes (Fig. 50).
(9) Depress heater core retaining clips (Fig. 51).
(10) Pull up on accelerator pedal and slide heater
core past (Fig. 52).(11) Depress brake pedal (Fig. 53) and remove
heater core from HVAC housing.
Fig. 46 HVAC Bolt-Up
Fig. 47 ABS MODULE
Fig. 48 Interconnect And Bracket
Fig. 49 Lower Silencer Boot
24 - 30 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When diagnosing electrical problems in the auxil-
iary rear heater or rear A/C system, refer to Group
8W, Wiring Diagrams.
When diagnosing problems in the auxiliary sys-
tems, refer to diagnostic sections for front heater A/C.
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT-A/C
REMOVAL
(1) Remove quarter trim panel, D-pillar, and head-
liner (Fig. 8). Refer to Group 23, Body.
(2) Remove screws securing D-pillar duct to quar-
ter panel. Pull duct up and away from unit.
(3) Remove screws securing duct to rear header
(Fig. 9).
(4) Remove screws securing duct to right and left
rails (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
AIR DISTRIBUTION DUCT-HEATER
REMOVAL
(1) Remove quarter trim panel and D-pillar (Fig.
8) and (Fig. 11). Refer to Group 23, Body.
(2) Remove screws securing lower heat duct to
housing.
INSTALLATION
For installation, reverse the above procedures.
Fig. 7 Rear Blower Switch
Fig. 8 Quarter Trim Panel
Fig. 9 Rear Crossover Duct
Fig. 10 Upper A/C Duct
NSHEATING AND AIR CONDITIONING 24 - 43
DESCRIPTION AND OPERATION (Continued)

CAUTION: Do not damage the evaporator insulation
liner during installation.
(3) Carefully install the evaporator and expansion
valve straight into the unit. Do not scratch the seal-
ing surfaces with the plumbing extension tube pilots.
(4) Determine the amount of old refrigerant oil
drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system.
(5) Carefully align the expansion valve onto the
pilot tubes of the plumbing extension (do not scratch
the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten
bolts to 2363 N´m (200630 inch pounds) torque.
(6) Install evaporator cover and blower scroll.
(7) Install quarter trim panel, evacuate/charge sys-
tem, and perform the performance test.
REAR AIR CONDITIONING LINES
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Hoist vehicle
(2) Remove compression fittings to the suction and
liquid lines located on the right, outboard side of the
underbody, rearward of the front crossmember. (Fig.
2)
(3) remove (1) bolt securing a/c lines to block
located on the right, outboard side of the underbody,
rearward of the rear wheel and tire. (Fig. 5)
(4) Remove (3) straps securing underbody lines.
(Fig. 1)
(5) Separate and remove a/c lines from vehicle.
INSTALLATION
(1) Before installation, replace all O-rings and gas-
kets. Coat all sealing surfaces with approved wax-
free refrigerant oil. Then, reverse the above
procedures.
(2) Evacuate and recharge system.
REAR HEATER A/C AIR OUTLETS
REMOVAL
Separate barrel from bezel by pulling outward.
INSTALLATION
For installation, push the outlet firmly into the
opening until it locks into place.
REAR HEATER-A/C AUXILIARY CONDENSER
If vehicle is equipped with a 3.3L or 3.8L engine
with rear heater and air conditioning, it will be
equipped with an auxiliary condenser. The auxiliarycondenser is mounted on the primary condenser in
front of the radiator. Both condenser must be
removed as an assembly and then separated.
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.
The condenser assembly must first be removed
from vehicle. Refer to CONDENSER ASSEMBLY
removal and installation in this section for service
procedures.
REMOVAL
(1) After condenser assembly removal, place on
bench for disassembly.
(2) Remove (1) bolt to liquid line on auxiliary con-
denser.
(3) Remove (4) attaching bolts and separate auxil-
iary from primary condenser. (Fig. 15)
INSTALLATION
(1) Before installation, replace all O-rings and gas-
kets. Coat all sealing surfaces with approved wax-
free refrigerant oil. Then, reverse the above
procedures.
(2) Evacuate and recharge system.
Fig. 15 3.3L/3.8L REAR HEAT-A/C AUXILIARY
CONDENSER
NSHEATING AND AIR CONDITIONING 24 - 45
REMOVAL AND INSTALLATION (Continued)

REAR HEATER A/C BLOWER MOTOR
REMOVAL
(1) Remove the right quarter trim panel and D-pil-
lar trim. Refer to Group 23, Body for service proce-
dures.
(2) Remove (5) screws securing the blower motor
housing to the rear of the HVAC housing (one screw
located on evaporator cover) (Fig. 16).
(3) Twist motor out of scroll housing.
(4) Disconnect blower motor wiring connector.
INSTALLATION
For installation, reverse the above procedures.
REAR HEATER-A/C CONTROL ILLUMINATION BULB
REMOVAL
(1) Remove rear heater-A/C control from trim
panel.
(2) On the back of control opposite from the wire
connectors, locate the bulb socket lug.
(3) Rotate the socket counterclockwise and pull the
socket from the control.
INSTALLATION
For installation, reverse the above procedures.
Refer to Group 8L, Lamps for bulb usage.
REAR HEATER A/C UNIT
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
WARNING: ON VEHICLES EQUIPPED WITH REAR
A/C, THE REFRIGERANT SYSTEM MUST BE EMP-
TIED BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Using a refrigerant recovery machine, remove
refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit.
(2) Hoist vehicle.
(3) Remove A/C lines at lower floor pan flange
(Fig. 17).
(4) Remove (3) A/C unit floor mounting nuts (Fig.
18).
(5) Lower vehicle.
(6) Remove right quarter trim panel and D-pillar
trim (Fig. 8). Refer to Group 23, Body.
(7) Remove screws securing air distribution duct to
the rear wheel housing (Fig. 19).
Fig. 16 Blower Motor
Fig. 17 A/C Lines
Fig. 18 A/C Mounting
24 - 46 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

NOTE: If the heater core was emptied and was not
prefilled, it is necessary to thermal cycle the vehicle
TWICE. The heater core is positioned higher than
the radiator fill cap. Therefore the heater core will
not gravity fill to level. To thermal cycle the vehicle,
it must be operated till the thermostat opens, then
turned off and allowed to cool. In order to verify
that the auxiliary unit is filled completely, the follow-
ing procedure can be used:
²Vehicle at room temperature.
²Engine is brought up to operating temperature.
²Front unit is OFF, temperature slides are at full
HEAT position.
²Engine is at idle.
²With rear blower motor ON HIGH
²Discharge air temperature, measured at the
dual register located on the C-pillar base, is between
57ÉC to 62ÉC (135É and 145É F).
REAR HEATER LINES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Partially drain engine cooling system. Refer to
Group 7, Engine Cooling.
(2) Loosen clamp at the front end of the hose
located at the right, outboard side of the underbody,
rearward of the front crossmember. (Fig. 2)
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple. If the hose
will not come off, slice the hose at the connector nip-
ple and peel off heater hose. This method will require
heater hose replacement.
CAUTION: When removing hoses from outlet nip-
ples, do not use excessive force. Outlet nipples
may become damaged and leak engine coolant.
(4) Compress insert in rear heater hose quick con-
nection and pull downward on hose. (Fig. 4)(5) Remove (3) straps securing underbody lines.
(Fig. 1)
(6) Separate and remove rear heater lines from
vehicle.
INSTALLATION
For installation, reverse the above procedures.
MODE DOOR
REMOVAL
(1) Remove A/C unit.
(2) Place unit on bench.
(3) Remove heater core.
(4) Remove blower scroll.
(5) Remove evaporator cover.
(6) Remove A/C line to expansion valve mounting
nut.
(7) Carefully pull evaporator out of housing.
(8) Remove mode door actuator and gear exten-
sion.
(9) Remove Heater-A/C housing clips and screws.
(10) Separate housing halves.
(11) Remove mode door.
INSTALLATION
For installation, reverse the above procedures.
MODE DOOR ACTUATOR
REMOVAL
(1) Remove A/C unit.
(2) Place unit on bench.
(3) Remove mode door actuator connector.
(4) Remove mode door actuator mounting screws
and remove actuator.
INSTALLATION
For installation, reverse the above procedures.
NSHEATING AND AIR CONDITIONING 24 - 49
REMOVAL AND INSTALLATION (Continued)