1996 CHRYSLER VOYAGER tow

INSTALLATION
(1) Place seat cushion pan in position in seat cover
and pad.
(2) Engage J-strip retainers to hold seat cover to
cushion pan.
(3) Place seat cushion pan in position on seat.
(4) Install bolts to hold seat cushion pan to seat
track.
(5) If equipped, install stowage bin.
(6) If equipped, install power seat track front and
rear cover.
(7) Install seat cushion side covers.
(8) Install bucket seat in vehicle.
BUCKET SEAT CUSHION SIDE COVER
REMOVAL
(1) Remove screws holding seat cushion side cover
to bucket seat (Fig. 11).
(2) Slide seat cushion rear listing toward the cen-
ter of the seat to gain access to rear screw.
(3) Remove screw holding rear of side cover to seat
cushion frame.
(4) Remove side cover from seat cushion.
(5) If equipped, disconnect wire connector from
power seat switch (Fig. 12).
INSTALLATION
(1) Place side cover in position on seat cushion.
(2) If equipped, connect wire connector into power
seat switch.
(3) Install screw to hold rear of side cover to seat
cushion frame.
(4) Install screws to hold seat cushion side cover to
bucket seat (Fig. 11).
BUCKET SEAT RECLINER ± MANUAL
REMOVAL
(1) Remove bucket seat cushion pan.
(2) Remove E-clip holding pin in seat track.
(3) Remove pin holding manual recliner to seat
track (Fig. 13).
(4) Remove nut holding recliner to seat back
frame.
(5) Remove recliner from seat.
INSTALLATION
(1) Place recliner in position on seat.
(2) Insert stud on seat back through hole in
recliner.
(3) Install nut to hold recliner to seat back frame.
(4) Install roll pin to hold manual recliner to seat
track (Fig. 13).
(5) Install E-clip to hold pin in seat track.
(6) Install bucket seat cushion pan.
Fig. 11 Bucket Seat Cushion Side Cover
Fig. 12 Power Seat Switch Wire Connector
Fig. 13 Bucket Seat Recliner ± Manual
NSBODY 23 - 13
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place cowl trim sill plate in position on vehicle.
(2) Engage hidden clips to hold cowl trim to cowl
panel.
(3) Install door sill plate.
FLOOR CARPET
REMOVAL
(1) Remove front seats.
(2) Remove front center console.
(3) Remove first rear seat.
(4) Remove second rear seat.
(5) Remove front cowl panels and sill plates.
(6) Remove sliding door sill plates.
(7) Remove rear door sill plate.
(8) Remove lower B-pillar trim covers.
(9) Remove D-pillar trim covers.
(10) Remove Quarter trim panels.(11) Remove floor escutcheons (Fig. 6).
(12) Remove push-in fasteners holding carpet to
floor in front seat area.
(13) Roll carpet from under instrument panel to
center of sliding door.
(14) R
oll carpet forward away from rear door open-
ing.
(15) Extract carpet through sliding door opening
(Fig. 7).
INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.
(4) Install push-in fasteners through carpet and
grommet into floor to hold carpet to floor in front
seat area.
Fig. 3 Cowl Cover
Fig. 4 Cowl Cover Retainers
Fig. 5 Cowl Trim
Fig. 6 Seat Escutcheons
23 - 26 BODYNS
REMOVAL AND INSTALLATION (Continued)

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)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)

(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Loosen center hinge bolts (Fig. 137).
(d) Move hinge fore or aft to position the sliding
door into the correct location.
(e) Tighten center hinge bolts.
(f) Verify alignment. Re-adjust as necessary.
(3) If the sliding door is low at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
138).
(e) Move hinge downward to raise the door.
(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment. Re-adjust as necessary.
(4) If the sliding door is low at the C-post;
(a) Open the door to mid-point of travel.
(b) Mark outline of center hinge on sliding door
to assist in making adjustments.
(c) Adjust the adjustment bolt up or down to
move the door position. (Fig. 137).
(d) Move hinge downward to raise the door.
(e) Tighten center hinge bolts.
(f) Verify alignment. Re-adjust as necessary.
(5) If the sliding door is high at the B-post;
(a) Remove access plug in the sliding door trim
panel.
(b) Open the door to mid-point of travel.
(c) Mark outline of lower roller arm bracket on
sliding door to assist in making adjustments.
(d) Loosen lower roller arm bracket bolts (Fig.
138).(e) Move hinge upward to raise the door.
(f) Tighten lower roller arm bracket bolts.
(g) Verify alignment. Re-adjust as necessary.
SEAL COMPRESSION
(1) Check seal compression at top and bottom of
B-post seal.
(2) Adjust seal compression at the top of the
B-post seal;
(a) Open door to mid-point of travel.
(b) Mark outline of upper roller arm on bracket
to assist in making adjustments.
(c) Loosen bolts holding upper roller arm to
bracket (Fig. 139)
(d) Decrease the length of the upper roller arm
to increase seal compression.
(e) Increase the length of the upper roller arm to
decrease seal compression.
(f) Tighten all upper roller arm bolts.
(g) Verify door alignment. Re-adjust as neces-
sary.
(3) Adjust seal compression at the bottom of B-post
seal.
(a) Open door to mid-point of travel.
(b) Mark outline of lower roller arm on lower
roller arm bracket to assist in making adjustments.
(c) Loosen bolts holding lower roller arm to
lower roller arm bracket.
(d) Pivot lower roller arm toward center of vehi-
cle to decrease seal compression.
(e) Pivot lower roller arm outward to increase
seal compression.
(f) Tighten lower roller arm bolts.
(g) Verify alignment. Re-adjust as necessary.
Fig. 138 Sliding Door Lower Roller Arm Bracket
Fig. 139 Sliding Door Upper Roller Arm
NSBODY 23 - 81
ADJUSTMENTS (Continued)

COOLDOWN TEST ENTRY
TO INITIATE TESTS:
²Set Blower motor ON HIGH
²Set Mode position to Panel
²Open all A/C outlets
²Set Temperature to Cold (Both slide pots if
equipped)
²Depress WASH and A/C simultaneously for 5
Seconds
NOTE: Prior to start of test, If the evaporator is
already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor
ON high for three minutes prior to starting test.
RESULTS:
²All LED's will turn on for 5 Seconds
²Cooldown Test is running when A/C and
RECIRC. are alternately flashing. If A/C and
RECIRC. are flashing simultaneously, Cooldown has
failed.
CALIBRATION DIAGNOSTICS AND
COOLDOWN ABORT
Test can be aborted by doing one of the following:
²Depressing Rear Window Defogger, RECIRC and
Rear Wiper buttons.
²Cycling Ignition OFF and then ON.
²Control will automatically abort after 15 min-
utes from the time Calibration Diagnostics and
Cooldown was entered.
The HVAC control module will return to normal
operation or may indicate unsuccessful Calibration
Diagnostics or Cooldown test by LED's flashing
simultaneously.
EEPROM DATA
Calibration Diagnostics, Cooldown Status and
evaporator temperature Fin Sensor values are stored
in an EEPROM memory internal to the control. The
microcomputer within the HVAC control module uses
this information:
²To determine if Cooldown needs to run
²For proper position of the Heater-A/C unit
assembly doors
ACTUATOR CALIBRATION AND
DIAGNOSTICS.
NOTE: Do not run actuators unless they are prop-
erly mounted on the HVAC control module.
Actuator end point calibration takes approximately
60 seconds. The REAR WIPER and INTERMITTENT
LED's will flash alternately during the test. The con-
trol will cycle the Blend actuator(s) to the Heat stopfirst then back to Cold. After the Blend actuator(s)
have been calibrated the Mode actuator will be cycled
to Defrost and then to Panel. Successful calibration
is defined as actuator travel falling within their min-
imum and maximum limits.
BLEND/PASSENGER ACTUATOR BACKGROUND
The Blend/Passenger Actuator can move the tem-
perature door in two directions. When the voltage at
Pin 12 of the control module is high, about 11.5 volts,
and the voltage at Pin 17 is low, about 1.5 volts, the
door will move towards the Heat position. When Pin
17 is High and Pin 12 is Low the door will move
towards the Cold position. When both Pins are high
or both Pins are low, the actuator will not move. The
Blend/Passenger feedback signal is a voltage signal
that is supplied by the actuator to the control. The
signal will be about 4.0 volts in the Heat position
and 1.0 volt in the Cold position. As the position of
the Blend/Passenger actuator changes, so will the
feedback signal. The feedback signal is necessary for
the correct positioning of the temperature door.
DRIVER ACTUATOR BACKGROUND
The Driver Actuator can move the temperature
door in two directions. When the voltage at Pin 15 of
the control module is high, about 11.5 volts, and the
voltage at Pin 13 is low, about 1.5 volts the door will
move towards the Cold position. When Pin 13 is High
and Pin 15 is Low the door will move towards the
Heat position. When both Pins are high or when both
Pins are low, the actuator will not move. The Driver
feedback signal is a voltage signal that is supplied by
the actuator to the control. The signal will be about
4.0 volts in the Heat position and 1.0 volt in the Cold
position. As the position of the Driver Actuator
changes, so will the feedback signal. The feedback
signal is necessary for the correct positioning of the
temperature door.
MODE ACTUATOR BACKGROUND
The Mode actuator can move the mode door in two
directions. When the voltage at Pin 18 of the control
module is high, about 11.5 volts, and the voltage at
Pin 12 is low, about 1.5 volts the door will move
towards the Panel position. When Pin 12 is High and
Pin 18 is Low the door will move towards the Defrost
position. When both Pin are high or when both Pins
are low, the actuator will not move. The Mode door
feedback signal is a voltage signal that is supplied by
the actuator to the control. The signal will be about
4.5 volts in the Panel position and 0.5 volts in the
Defrost position. As the position of the Mode actuator
changes, so will the feedback signal. The feedback
signal is necessary for the correct positioning of the
mode door.
24 - 8 HEATING AND AIR CONDITIONINGNS
DIAGNOSIS AND TESTING (Continued)

The high pressure service port is located on the liq-
uid line near the strut tower. The low pressure ser-
vice port is located on the suction line near the
compressor manifold.
When servicing a system, it is required that an air
conditioning charging recovery/recycling machine be
used (Fig. 8). Contact an automotive service equip-
ment supplier for proper equipment. Refer to the
operating instructions provided with the equipment
for proper operation.
A manifold gauge set (Fig. 9) must also be used in
conjunction with the charging and/or recovery/recy-
cling device. Only use gauges that have not been
used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back
flow valves at the service port connector ends. This
will prevent refrigerant R-134a from being released
into the atmosphere.
R-134a refrigerant requires a special type of com-
pressor oil. When adding oil, make sure to use the oil
that is specified on the under hood label.
Due to the different characteristics of R-134a it
requires all new service procedures.
The use of R-134a will have a positive environmen-
tal impact due to it's zero ozone depletion and low
global warming impact.
CHARGING REFRIGERANT SYSTEM
CAUTION: Do not overcharge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for leaks and
evacuated, a refrigerant (R-134a) charge can be
injected into the system.
Charge Determination Chart
Fig. 8 Refrigerant Recovery/Recycling Station
(Typical)
NSHEATING AND AIR CONDITIONING 24 - 17
SERVICE PROCEDURES (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)