1996 CHRYSLER VOYAGER ABS

probe will drop the temperature 7ÉC (20ÉF) in two
minutes. If the Evaporator Probe is found to be
faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat
test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures table.
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PRESSURE TRANSDUCER
The work area temperature must not be below
10ÉC (50ÉF) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the
wire connector is clean of corrosion and connected
properly.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Install scan tool (DRB):
²Go to main menu
²Select stand alone scan tool (DRB)
²Select refer to the proper year diagnostics
²Select climate control
²Select sensor display
²Select A/C high side volts
For A/C system to operate a voltage between .451
(Low Pressure Cutout) to 4.519 (High Pressure Cut-
out is required. Voltages outside this range indicate a
low or high pressure condition andwill notallow
the compressor to cycle.
Refer to the A/C Pressure Transducer Voltage table
for the appropriate condition(s):
A/C PERFORMANCE TEMPERATURES
AMBIENT TEMPERATURE 21ÉC
(70ÉF)26.5ÉC
(80ÉF)32ÉC
(90ÉF)37ÉC
(100ÉF)43ÉC
(110ÉF)
AIR TEMPERATURE AT LEFT
CENTER PANEL OUTLET1-8ÉC
(34-46ÉF)3-9ÉC
(37-49ÉF)4-10ÉC
(39-50ÉF)6-11ÉC
(43-52ÉF)7-18ÉC
(45-65ÉF)
COMPRESSOR DISCHARGE
PRESSURE AFTER THE FILTER
DRIER1034-1724
kPa
(150-250
PSI)1517-2275
kPa
(220-330
PSI)1999-2620
kPa
(290-380
PSI)2068-2965
kPa
(300-430
PSI)2275-3421
kPa
(330-496
PSI)
EVAPORATOR SUCTION
PRESSURE103-207 kPa
(15-30 PSI)117-221 kPa
(17-32 psi)138-241 kPa
(20-35 PSI)172-269 kPa
(25-39 PSI)207-345 kPa
(30-50 PSI)
24 - 12 HEATING AND AIR CONDITIONINGNS
DIAGNOSIS AND TESTING (Continued)

²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set in 100 percent outside air
²Full Panel Mode
²Blower motor ON HIGH
²A/C in the ON position
²Front Windows Open.
²Rear Air Off (If Equipped)
CAUTION: A leak detector designed for R-12 refrig-
erant will not detect leaks in a R-134a refrigerant
system.
(4) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the recirculating air door opening
or a heat duct.
If a thorough leak check has been completed with-
out indication of a leak, proceed to System Charge
Level-Check or Fill.
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER
REMOVAL
(1) Disconnect the wire connector at the pressure
transducer.
(2) Using an open end wrench, remove the trans-
ducer from the liquid line (Fig. 11).
INSTALLATION
(1) Replace transducer O-ring.
(2) For installation, reverse the above procedures.
A/C SERVICE PORTS
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
The High Side service port is serviceable, the Low
Side is not serviceable.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Recover A/C system refrigerant.
(3) Unscrew the High Side service port from the
liquid line.
(4) Remove O-ring
INSTALLATION
For installation, reverse the above procedures.
²Install new O-ring.
²Evacuate and recharge A/C system.
BLEND-AIR DOOR ACTUATOR
REMOVAL
The air conditioning system can be equipped with
either a standard, single blend-air door actuator, or it
can be equipped with dual actuators. The dual sys-
tem has separate blend-air controls. This allows for
separate control of the driver's side air, and the pas-
senger side air (Fig. 12).
(1) Remove the lower left side steering column
cover. Refer to Group 8E, Instrument Panel and Sys-
tems.
(2) Remove ABS control module (Fig. 13).
(3) Remove blend-air actuator connector.
(4) Remove blend-air actuator (Fig. 14).
INSTALLATION
(1) For installation, reverse the above procedures.
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
24 - 20 HEATING AND AIR CONDITIONINGNS
SERVICE PROCEDURES (Continued)

(2) Perform the HVAC Control Calibration Diag-
nostic and Cooldown test. Repeating the test is nec-
essary to clear the fault codes.
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL
(1) Remove glove box. Refer to Group 8E, Instru-
ment Panel and Systems.
(2) Remove (4) hex head screws to blower motor
cover (Fig. 15).
(3) Disconnect blower motor wiring.
(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) Disconnect and isolate negative battery cable.
Fig. 13 ABS Control Module
Fig. 14 Blend-Air Actuator
Fig. 15 Blower Motor Cover
Fig. 16 Wiring Grommet
Fig. 17 Feeding Wiring Through Housing
NSHEATING AND AIR CONDITIONING 24 - 21
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)

CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant.
(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.
INSTALLATION
For installation, reverse the above procedures.
LIQUID LINE
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) Remove ground wire at dash panel.
(6) Remove the nut retaining the refrigerant line
sealing plate to the expansion valve (Fig. 39).
(7) Remove the stud from the expansion valve (Fig.
40).
(8) Remove liquid line from expansion valve.
(9) Cover the openings to prevent contamination.
(10) Disconnect wire connector at pressure trans-
ducer.
(11) Remove liquid line mounting bracket at right
frame rail.
(12) Using access slot between radiator crossmem-
ber and grille, loosen liquid line mounting plate at
filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to
remove line. The replacement line is a two-piece
assembly.
(13) Remove the old O-rings.
INSTALLATION
For installation, reverse the above procedures.
²Install the stud to the evaporator sealing plate
and tighten 7 to 11 N´m (64 to 96 in. lbs.) torque.
²Install new O-rings.
²Install two-piece line in place of original part.
²A
ssemble line halves after it is installed on vehicle.²Evacuate and recharge A/C system.
MODE DOOR ACTUATOR
REMOVAL
(1) Remove the lower left side steering column
cover. Refer to Group 8E, Instrument Panel and Sys-
tems.
(2) Remove ABS control module (Fig. 56).
(3) Remove mode actuator connector (Fig. 57).
(4) Remove mode door actuator (Fig. 58).
INSTALLATION
(1) For installation, reverse the above procedures.
Fig. 55 Lower Heater Hose
Fig. 56 ABS Control Module
Fig. 57 Mode Door Actuator Connector
24 - 32 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

pressor is driven off the back of the power steering
pump. A rubber flex coupling transfers the power from
the power steering pump to the compressor clutch.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The High Pressure Relief Valve prevents damage
to the air conditioning system if excessive pressure
develops. Excessive pressure can be caused by con-
denser air flow blockage, refrigerant overcharge, or
air and moisture in the system.
The high pressure relief valve vents only a small
amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the
refrigerant is conserved in the system. The valve is
calibrated to vent at a pressure of 3450 to 4140 kPa
(500 to 600 psi). If a valve has vented a small
amount of refrigerant, it does not necessarily mean
the valve is defective.
The High Pressure Relief Valve is located on the
compressor manifold at the discharge passage.
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.
CONDENSATE DRAIN
Condensation from the evaporator housing is
drained through the dash panel and on to the
ground. This drain must be kept open to prevent
water from collecting in the bottom of the housing.
If the drain is blocked condensate cannot drain,
causing water to back up and spill into the passenger
compartment. It is normal to see condensate drain-
age below the vehicle.
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain ample temperature levels from the
heating-A/C system, the cooling system must be in
proper working order. Refer to Group 0, Lubrication
and Maintenance or Group 7, Cooling System of this
manual.
The use of a bug screen is not recommended. Any
obstructions forward of the condenser can reduce the
effectiveness of the air conditioning system.
EVAPORATOR PROBE
The Evaporator probe is located on the HVAC. The
probe prevents evaporator freeze-up by signaling the
Powertrain Control Module to cycle the compressor
ON and OFF. The probe monitors the temperature of
the refrigerant after expansion.
The evaporator probe is inserted into the evapora-
tor between the coils. The probe is a sealed unit and
cannot be adjusted or repaired. It must be replaced if
found defective.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HVAC CONTROL MODULE
The HVAC control module regulates the operation
of the various actuator motors. The actuator motors
are used to move the mode, blend- air, and recirc.
doors (Fig. 2).
The control module is included in the A/C control
head located on the instrument panel. The control
head includes the blower speed switch, rear wiper
NS/GSHEATING AND AIR CONDITIONING 24 - 3
DESCRIPTION AND OPERATION (Continued)

capacity of the system and consequently result in
higher discharge air temperatures.
NOTE: The oil used in the Denso 2.5L Turbo Diesel
and the Denso 2.0L gasoline engine compressors is
ND-8 PAG R134a refrigerant oil. Only refrigerant oil
of the same type should be used to service the sys-
tem. 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 contamina-
tion from dirt and moisture. Refrigerant oil will
quickly absorb any moisture it comes in contact
with. 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 reli-
ability 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 compressor is drained through the
suction port or by removing the sump bolt on top of
the compressor, refer to Compressor Removal and
Installation procedures. The filter-drier must be
replaced along with the ruptured part. The oil capac-
ity of the system, minus the amount of oil still in the
remaining components, can be measured and poured
into the suction port of the compressor.
Example: The evaporator retains 50 ml (1.7 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.).
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 the Denso 2.5L Turbo Diesel and Denso 2.0L gas-
oline engine compressors is ND-8 PAG compressor
oil. For gasoline vehicles still using R-12 refrigerant,
use ND8 PAG compressor oil.
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 calibration.
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibra-
tion compensates for mechanical variations in the
REFRIGERANT OIL CAPACITIES
REFRIGERANT OIL CAPACITIES
COMPONENT ML OZ
Compressor 135 ml 4.5 oz
Filter-Drier 30 ml 1.0 oz
Condenser 30 ml 1.0 oz
Evaporator 50 ml 1.7 oz
NS/GSHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)

²No charge
²Compressor not operating
Verify that the test was done with the evaporator
at room temperature. The test consists of starting
the compressor and measuring the time it takes for
the evaporator temperature to fall 7ÉC (20ÉF). If the
compressor has been running, the evaporator is cold
already and will not be capable of falling 7ÉC (20ÉF).
If the test was run with a cold evaporator, turn A/C
off and turn the blower motor switch to high position
for 3 to 5 minutes till the evaporator is to room tem-
perature. Then repeat the Calibration Diagnostic and
Cooldown test.
If refrigerant system is performing properly and
the system will not pass test. Repeat the Calibration
Diagnostic and Cooldown test to determine if the
evaporator temperature FIN sensor has developed an
open or a short circuit. If the HVAC control module
still passes Calibration test, verify Cooldown test
manually with a pocket thermometer. The outlet air
temperature must drop at least 7ÉC (20ÉF) within
two minutes. If the vehicle passes with the manual
thermometer, take HVAC control to level 4 (evapora-
tor probe temperature readout) and repeat the
Cooldown test. Ensure the evaporator is at room tem-
perature before starting test. Check if evaporator
probe will drop the temperature 7ÉC (20ÉF) in two
minutes. If the Evaporator Probe is found to be
faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat
test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.
(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures chart (Fig. 7).
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PRESSURE TRANSDUCER
The work area temperature must not be below
10ÉC (50ÉF) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the
wire connector is clean of corrosion and connected
properly.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Install scan tool (DRB):
²Go to main menu
²Select stand alone scan tool (DRB)
²Select refer to the proper year diagnostics
²Select climate control
²Select sensor display
²Select A/C high side volts
For A/C system to operate a voltage between .451
(Low Pressure Cutout) to 4.519 (High Pressure Cut-
out is required. Voltages outside this range indicate a
low or high pressure condition andwill notallow
the compressor to cycle.
The following chart denotes voltages and the
appropriate condition(s):
NS/GSHEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)