1996 CHRYSLER VOYAGER cooling

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)

INSTALLATION
NOTE: Inspect Cooling Module for presence of
seals. Verify seals are available for re-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) Torque the following components to specifica-
tions:²Liquid line at filter/drier ± 45 in. lbs.610.
²Upper discharge line at condenser ± 180 in. lbs.
620
²Lower liquid line to condenser ± 180 in. lbs.6
20.
²(2) lower, condenser mounting bolts ± 45 in. lbs.
610.
²(2) upper, condenser mounting bolts ± 45 in. lbs.
610.
(3) Evacuate and charge system.
DISCHARGE LINE
REMOVAL
(1) Recover A/C system refrigerant.
(2) Remove discharge line mounting nut at com-
pressor (Fig. 34).
(3) Remove discharge line at the top fitting on the
condenser (Fig. 35).
Fig. 30 Liquid Line
Fig. 31 Filter-Drier
Fig. 32 Upper Discharge Line
Fig. 33 Condenser Removal
24 - 26 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
For installation, reverse the above procedures.
Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tightenheater core tube retaining plate to 361 N´m (276
9 in. lbs.) torque.
HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Drain engine cooling system. Refer to Group 7,
Engine Cooling.
(2) Loosen clamps at each end of heater hose to be
removed (Fig. 54) and (Fig. 55).
Fig. 50 Heater Core Plate And Tubes
Fig. 51 Depress Clips
Fig. 52 Accelerator Pedal
Fig. 53 Brake Pedal
Fig. 54 Upper Heater Hose
NSHEATING AND AIR CONDITIONING 24 - 31
REMOVAL AND INSTALLATION (Continued)

EVAPORATOR AND EXPANSION VALVE
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: THE REFRIGERANT SYSTEM MUST BE
EMPTY BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Remove right quarter trim panel and D-pillar
trim. Refer to Group 23, Body.
(2) Remove fan A/C distribution duct.
(3) Remove rear A/C unit.
(4) Remove blower scroll.
(5) Remove evaporator cover (Fig. 12).
(6) Remove the nut that mounts the refrigerant
plumbing block to the expansion valve (Fig. 13).
(7) Carefully pull the evaporator and expansion
valve straight out of unit (Fig. 14). Do not scratch
the sealing surfaces with the plumbing extension
tube pilots.
(8) Remove and discard the O-rings between the
plumbing extension and the expansion valve.
(9) Cover the plumbing extension sealing surface
to prevent contamination.
(10) Bring evaporator and expansion valve to a
clean work space.
(11) Remove two 1/4-20 Torx Head screws.
(12) Remove expansion valve.
(13) Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION
(1) Replace the O-rings.(2) Hold expansion valve against evaporator seal-
ing plate (do not scratch the sealing surface). Install
two screws and tighten to 1163 N´m (100630 inch
pounds) torque.
Fig. 11 Rear Heat-A/C UnitFig. 12 Evaporator Cover
Fig. 13 Expansion Valve
Fig. 14 Evaporator Removal
24 - 44 HEATING AND AIR CONDITIONINGNS
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)

HEATING AND AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
SAFETY PRECAUTIONS AND WARNINGS.... 2
DESCRIPTION AND OPERATION
A/C PRESSURE TRANSDUCER............ 2
A/C SERVICE PORTS.................... 2
AIR DISTRIBUTION DUCTS............... 2
COMPRESSOR......................... 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................ 3
SIDE DOOR HEATER A/C OUTLETS........ 4
SIDE WINDOW DEMISTER............... 4
SYSTEM AIRFLOW..................... 4
SYSTEM OIL LEVEL..................... 4
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST............... 11
A/C PRESSURE TRANSDUCER........... 11
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST..................... 5
BLOWER MOTOR AND WHEEL ASSEMBLY . 12
COMPRESSOR CLUTCH/COIL............ 12
COMPRESSOR NOISE DIAGNOSIS........ 12
EXPANSION VALVE.................... 14
HEATER PERFORMANCE TEST........... 14
HVAC CONTROL DIAGNOSTIC CONDITIONS . 9
SYSTEM CHARGE LEVEL TEST........... 15SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM....... 17
EVACUATING REFRIGERANT SYSTEM..... 17
R-134a REFRIGERANT.................. 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS.......................... 18
SYSTEM LEAK CHECKING............... 19
THERMOCOUPLE PROBE............... 18
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER........... 19
A/C SERVICE PORTS................... 19
BLEND-AIR DOOR ACTUATOR........... 20
BLOWER MOTOR AND WHEEL ASSEMBLY . 20
BLOWER MOTOR RESISTOR BLOCK...... 21
BLOWER MOTOR WHEEL............... 22
COMPRESSOR (2.5L TURBO DIESEL)..... 22
CONDENSER ASSEMBLY................ 23
DISCHARGE LINE..................... 23
EVAPORATOR PROBE.................. 24
EXPANSION VALVE.................... 25
FILTER-DRIER ASSEMBLY............... 26
HEATER A/C UNIT HOUSING............. 26
HEATER CORE........................ 26
HEATER HOSES....................... 28
LIQUID LINE......................... 28
MODE DOOR ACTUATOR................ 29
RECIRC DOOR ACTUATOR.............. 30
SIDE WINDOW DEMISTER DUCTS........ 29
SUCTION LINE........................ 29
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION......... 30
GENERAL INFORMATION
INTRODUCTION
The Heater, or Heater and Air Conditioning sys-
tems share many of the same components. This
group will deal with both systems together when
component function is common, and separately when
they are not.
For proper operation of the instrument panel con-
trols, refer to the Owner's Manual provided with the
vehicle.All vehicles are equipped with a common Heater
A/C unit housing assembly. When the vehicle has
only a heater system, the evaporator and recirculat-
ing air door are omitted.
An optional zone control HVAC unit is available.
This unit has dual blend-air doors that can be regu-
lated independently of each other. The temperature
setting can be different from driver's side to passen-
ger side.
NS/GSHEATING AND AIR CONDITIONING 24 - 1

SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
SONAL INJURY CAN RESULT.
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
DESCRIPTION AND OPERATION
AIR DISTRIBUTION DUCTS
The air distribution ducts for the A/C, Heater,
Defroster, and Second Seating Air Distribution arenot serviceable in vehicle. The procedures for service
of these ducts are covered in Group 8E, Instrument
Panel and Gauges.
The only ducts that are serviceable in the vehicle
are the side window demister ducts and the ducts
that feed the front door outlets for the first rear pas-
senger(s) seating. To service the door ducts refer to
Group 23, Body.
A/C PRESSURE TRANSDUCER
The A/C Pressure Transducer (Fig. 1) monitors the
refrigerant gas pressure on the high side of the sys-
tem. The transducer is located on the liquid line. The
pressure transducer turns off the voltage to the com-
pressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor.
The transducer also is used to adjust condenser fan
speeds and will turn off compressor at high refriger-
ant pressures. The pressure transducer is a sealed
factory calibrated unit. It must be replaced if defec-
tive. O-ring replacement is required whenever the
pressure transducer is serviced. Be sure to use the
O-ring specified for the transducer.
A/C SERVICE PORTS
The A/C service port valve cores are located within
the A/C lines. The High Side (Discharge) valve ser-
vice port is located on the liquid line near the right
strut tower. The Low Side (Suction) valve service
port is located on the suction line near the compres-
sor.
The High Side service port is a two piece port and
is serviceable. The Low Side service port is not ser-
viceable, and the suction line would have to be
replaced.
COMPRESSOR
The A/C compressor for the 2.5L Turbo Diesel, is
located on the front side of the engine block. It is
mounted to the engine block by four bolts. The com-
Fig. 1 A/C Pressure Transducer
24 - 2 HEATING AND AIR CONDITIONINGNS/GS
GENERAL INFORMATION (Continued)