1996 CHRYSLER VOYAGER WIPER

(4) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing five times.
The evaporator probe is open.
(1) Using a voltmeter, check Pin 1 of the evapora-
tor probe wiring connector for 0.1 - 4.75 volts. If OK,
go to Step 2. If not OK, if greater than 4.75 volts
check for loose or corroded connector, open circuit
and repair as necessary.
(2) Using a ohmmeter, check Pin 2 for a good
ground, If OK, go to Step 3. If not OK, check for loose
or corroded connector, open or shorted circuit and
repair as necessary.
(3) If ground and power circuit are OK, replace
Evaporator Probe.
(4) Once repairs are completed, press the intermit-
tent button about 5 seconds until all LED's light to
remove fault code from memory. Then repeat the Cal-
ibration Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing six times. The
evaporator probe is shorted.
(1) Using a voltmeter, check Pin 1 of the evapora-
tor probe wiring connector for 0.1 - 4.75 volts. If OK,
go to Step 2. If less than 0.1 volts, check for loose or
corroded connector, open or shorted circuit and repair
as necessary.
(2) Using a ohmmeter, check Pin 2 for a good
ground, If OK, go to Step 3. If not OK, check for
shorted circuit and repair as necessary.
(3) If ground and power circuit are OK, replace
Evaporator Probe
(4) Once repairs are completed, press the intermit-
tent button about 5 seconds until all LED's light to
remove fault code from memory. Then repeat the Cal-
ibration Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing seven times.
The Driver's temperature actuator on a zone
system did not reach cold stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check at the temperature
door actuator wiring connector, check Pin 1 for bat-
tery voltage. Move the HVAC control from cold to the
hot position, check Pin 4 voltage it should change
from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, goto Step 3. If not OK, check for loose or corroded con-
nector, open or shorted circuit and repair as neces-
sary.
(3) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 4. If not OK, repair as necessary.
(4) Check for binding doors, if door are binding
repair as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing eight times.
The Driver's temperature actuator on a zone
system did not reach hot stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check at the temperature
door actuator wiring connector, check Pin 1 for bat-
tery voltage. Move the HVAC control from hot to cold
position, Pin 4 voltage it should change from 3.5 - 4.5
volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3.
If not OK, check for loose or corroded connector, open
or shorted circuit and repair as necessary.
(3) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 4. If not OK, repair as necessary.
(4) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing nine times.
The HVAC control module, has a internal
failure.
(1) Replace the HVAC control module.
(2) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration and testing the A/C and
RECIRC LED flashing simultaneously. Failed
Cooldown test.
(1) Determine if the refrigerant system is operat-
ing correctly:
²Check the outlet air temperature
²Feel the compressor suction plumbing, is it hot?
(2) If not OK, go to Step 3. If OK, repeat the Cal-
ibration Diagnostic and Cooldown test.
(3) If system does not seem to be operating cor-
rectly, perform diagnostics for poor performance:
²Low refrigerant charge
24 - 10 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)

(4) Remove grommet for wiring (Fig. 16). Feed wir-
ing through blower housing (Fig. 17).
(5) Remove mounting screws for blower motor (Fig.
18).(6) Allow the blower assembly to drop down, and
remove assembly from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
(1) Open hood.
(2) Locate and remove the wire connector from the
blower resistor block. Block is located at the back of
the engine compartment on the passenger side of the
vehicle under the wiper module (Fig. 19).
NOTE: It is not necessary to remove the wiper
module to access the resistor block.
WARNING: THE RESISTOR BLOCK MAY BE HOT.
DO NOT ATTEMPT TO SERVICE THE RESISTOR
BLOCK IF THE SYSTEM HAS BEEN RUNNING
RECENTLY. LET THE SYSTEM COOL DOWN
BEFORE REPAIRS ARE INITIATED.
Fig. 15 Blower Motor Cover
Fig. 16 Wiring Grommet
Fig. 17 Feeding Wiring Through Housing
Fig. 18 Blower Motor Screws
Fig. 19 Resistor Block Removal
NS/GSHEATING AND AIR CONDITIONING 24 - 21
REMOVAL AND INSTALLATION (Continued)

(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.
(2) Remove liquid line at filter-drier (Fig. 21).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Drain engine coolant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
Installation procedures. Plug coolant lines.(6) Remove suction and liquid lines at the expan-
sion valve (Fig. 27).
(7) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Systems.
(8) Remove heater ducts.
(9) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(10) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 30).
(11) Disconnect the HVAC housing wiring harness.
(12) 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.
31).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 32).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 33)
(7) Pinch off heater lines under the hood.
Fig. 30 HVAC Bolt-Up
24 - 26 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)