1996 CHRYSLER VOYAGER air condition

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)

BLOWER MOTOR AND WHEEL ASSEMBLY
VIBRATION AND/OR NOISE DIAGNOSIS
The blower speed switch, in conjunction with the
resistor block, supplies the blower motor with varied
voltage.
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater A/C
housing.
Refer to the Blower Motor Vibration/Noise chart in
this section for diagnosis.
COMPRESSOR NOISE DIAGNOSIS
Excessive noise while the A/C is being used, can be
caused by loose mounts, clutch, or high operating
pressure. Verify compressor drive belt condition,
proper refrigerant charge and head pressure before
compressor repair is performed.
COMPRESSOR CLUTCH/COIL
The air conditioning compressor clutch electrical
circuit is controlled by the Powertrain Control Mod-ule. It is located in the engine compartment outboard
of the battery.
If the compressor clutch does not engage verify
refrigerant charge.
If the compressor clutch still does not engage check
for battery voltage at the pressure transducer located
on the liquid line. If voltage is not detected, refer to:
²Group 8W, Wiring diagrams.
²Powertrain Diagnostic Procedures manual for
diagnostic information.
If voltage is detected at the pressure transducer,
connect pressure transducer and check for battery
voltage between the compressor clutch connector ter-
minals.
If voltage is detected, perform A/C Clutch Coil
Tests.
TESTS
(1) Verify battery state of charge. (Test indicator in
battery should be green).
(2) Connect an ampmeter (0-10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch.
(3) With A/C control in A/C mode and blower at
low speed, start the engine and run at normal idle.
(4) The A/C clutch should engage immediately and
the clutch voltage should be within two volts of the
battery voltage. If the A/C clutch does not engage,
test the fuse.
(5) The A/C clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch
coil. This is with the work area temperature at 21ÉC
(70ÉF). If voltage is more than 12.5 volts, add electri-
cal loads by turning on electrical accessories until
voltage reads below 12.5 volts.
Fig. 7 A/C PERFORMANCE TEMPERATURES
VOLTAGE CONDITION
0 Transducer faulty or no voltage
from PCM
.150 to .450 Transducer good/Low Pressure
Cutout condition
.451 to 4.519 Normal operating condition
4.520 to 4.850 Transducer good/High
Pressure Cutout condition
5 Transducer faulty
24 - 12 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)

Blower Motor Noise/Vibration Diagnosis
NS/GSHEATING AND AIR CONDITIONING 24 - 13
DIAGNOSIS AND TESTING (Continued)

(6) If coil current reads zero, the coil is open and
should be replaced. If the ammeter reading is 4
amperes or more, the coil is shorted and should be
replaced. If the coil voltage is not within two volts of
the battery voltage, test clutch coil feed circuit for
excessive voltage drop.
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.
TESTS
NOTE: Expansion valve tests should be performed
after compressor tests.
Review Safety Precautions and Warnings in this
group. The work area and vehicle temperature must
be 21ÉC to 27ÉC (70ÉF to 85ÉF). To test the expansion
valve:
NOTE: Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set heater A/C control to A/C, full heat,
FLOOR, and high blower.
(4) Start the engine and allow to idle (1000 rpm).
After the engine has reached running temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the evaporator.
(5) I
f the refrigerant charge is sufficient, discharge
(high pressure) gauge should read 965 to 1655 kPa (140
to 240 psi). Suction (low pressure) gauge should read
140 kPa to 207 kPa (20 psi to 30 psig). If system cannot
achieve proper pressure readings, replace the expan-
sion valve. If pressure is correct, proceed with test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(6) If suction side low pressure is within specified
range, freeze the expansion valve control head for 30
seconds. Use a super cold substance (liquid CO2).Do
not spray R-134a Refrigerant on the expansion
valve for this test.Suction side low pressure should
drop by 10 psi. If not, replace expansion valve.(7) Allow expansion valve to thaw. The low pres-
sure gauge reading should stabilize at 140 kPa to
240 kPa (20 psi to 30 psig). If not, replace expansion
valve.
(8) When expansion valve test is complete, test
A/C overall performance. Remove all test equipment
before returning vehicle to use.
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
Review Safety Precautions and Warnings in this
group before performing the following procedures.
Check the coolant level, drive belt tension, vacuum
line connections, radiator air flow and fan operation.
Start engine and allow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing cap. Place a rag over the cap and
turn it to the first safety stop. Allow pressure to
escape through the overflow tube. When the system
stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With engine idling at normal running temperature,
set the control to maximum heat, floor, and high
blower setting. Using a test thermometer, check the
air temperature coming from the floor outlets, refer
to Temperature Reference chart.
If the floor outlet air temperature is insufficient,
refer to Group 7, Cooling Systems for specifications.
Both heater hoses should be HOT to the touch (cool-
ant return hose should be slightly cooler than the
supply hose). If coolant return hose is much cooler
than the supply hose, locate and repair engine cool-
ant flow obstruction in heater system.
TEMPERATURE REFERENCE CHART
AMBIENT TEMP.MINIMUM FLOOR
OUTLET TEMP.
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
24 - 14 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)

POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pinched or kinked heater hoses.
(2) Improper heater hose routing.
(3) Plugged heater hoses or supply and return
ports at cooling system connections, refer to Group 7,
Cooling System.
(4) Plugged heater core.
(5) Air locked heater core.
(6) If coolant flow is verified and outlet tempera-
ture is insufficient, a mechanical problem may exist.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl air intake.
(2) Obstructed heater system outlets.
(3) Blend-air door not functioning properly.
TEMPERATURE CONTROL
If temperature cannot be adjusted with the TEMP
lever on the control panel, the following could require
service:
(1) Blend-air door binding.
(2) Faulty blend-air door motor.
(3) Improper engine coolant temperature.
(4) Faulty Instrument Panel Control.
SYSTEM CHARGE LEVEL TEST
The procedure below should be used to check
and/or fill the refrigerant charge in the air condition-
ing system.
NOTE: The amount of R134a refrigerant that the air
conditioning system holds is 0.96 kg (34 oz. or 2.13
lbs.).
NOTE: Low Charge, condition may be described
as:
²Loss of A/C performance
²Fog from A/C outlets
²evaporator may have a HISS sound
There are two different ways the system can be
tested:
²With a scan tool (DRB), thermocouple and the
Charge Determination Graph. Use the scan tool
(DRB) diagnostic topic: Engine±System Monitors, A/C
Pressure.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Graph.
It is recommended to use the gauges or reclaim/re-
cycle equipment.
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAEREQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF
ACCIDENTAL SYSTEM DISCHARGE OCCURS, VEN-
TILATE WORK AREA BEFORE RESUMING SERVICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME
MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO
BE COMBUSTIBLE AT ELEVATED PRESSURES.
THESE MIXTURES ARE POTENTIALLY DANGER-
OUS AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
(1) Establish your preferred method of measuring
liquid line pressure. Use a manifold gauge set or a
DRB scan tool.
(2) A
ttach a clamp-on thermocouple (Professional
Service Equipment 66-324-0014 or 80PK-1A) or equiv-
alent to the liquid line. It must be placed as close to
the A/C Pressure Transducer as possible to observe liq-
uid line temperature. Refer to ªThermocouple Probeº in
this section for more information on probe.
(3) The vehicle must be in the following modes:
²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set to Outside Air
²Panel Mode
²Full Cool
²High Blower motor, (vehicle equipped with rear
A/C turn rear blower motor ON HIGH)
²A/C Button in the ON position
²Vehicle Windows Open.
²Recirc. button turned OFF
(4) Operate system for a couple of minutes to allow
the system to stabilize.
(5) Set system pressure to about 1793 kPa (260
psi) by placing a piece of cardboard over part of the
front side of the condenser. To place cardboard prop-
erly, remove the upper radiator-condenser cover.
Insert cardboard between condenser and radiator
front. This will maintain a constant pressure.
(6) Observe Liquid Line pressure and Liquid line
temperature. Using theCharge Determination
Chartdetermine where the system is currently oper-
ating. If the system is in the undercharged region,
ADD 0.057 Kg. (2 oz.) to the system and recheck
readings. If the system is in the overcharged region,
RECLAIM 0.057 Kg. (2 oz.) from the system and
recheck readings. Continue this process until the sys-
tem readings are in the proper charge area on the
Charge Determination Chart.
(7) The same procedure can be performed using
the scan tool (DRB). To determine liquid line pres-
sure, attach the scan tool, go to System Moni-
tors±A/C Pressure. Observe liquid line pressure from
A/C Pressure Transducer on digital display and digi-
tal thermometer. Refer toCharge Determination
Chartand determine where the system is operating.
NS/GSHEATING AND AIR CONDITIONING 24 - 15
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
R-134a REFRIGERANT
This vehicle uses a new type of refrigerant called
R-134a. It is a non-toxic, non-flammable, clear color-
less liquefied gas.
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause
compressor failure, refrigerant oil to sludge and/or
poor performance.Never add any other type of
refrigerant to a system designed to use R-134a
refrigerant. System failure will occur.
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 setshould 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.
Charge Determination Chart
Fig. 8 Refrigerant Recovery/Recycling Station
(Typical)
24 - 16 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)

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.
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 manifold gauge set.
(2) Measure refrigerant 0.96 kg (34 oz. or 2.13 lb.)
and heat to 52ÉC (125ÉF) with the charging station.
Refer to the instructions provided with the equip-
ment being used.
(3) Open the suction and discharge valves. Open
the charge valve to allow the heated refrigerant to
flow into the system. When the transfer of refriger-
ant has stopped, close the suction and discharge
valve.
(4) If all of the charge did not transfer from the
dispensing device, run engine at a high idle (1400
rpm). Set the A/C control to A/C, low blower speed,
and open windows. If the A/C compressor does not
engage, test the compressor clutch control circuit andcorrect any failure. Refer to Group 8W, Wiring Dia-
grams.
(5) Open the suction valve to allow the remaining
refrigerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Close all valves and test the A/C system perfor-
mance.
(7) Disconnect the charging station or manifold
gauge set. Install the service port caps.
EVACUATING REFRIGERANT SYSTEM
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
If a compressor designed to use R-134a refrigerant
is left open to the atmosphere for an extended period
of time. It is recommended that the refrigerant oil be
drained and replaced with new oil or a new compres-
sor be used. This will eliminate the possibility of con-
taminating the refrigerant system.
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be filled. Moisture and air mixed with the refrig-
erant will raise the compressor head pressure above
acceptable operating levels. This will reduce the per-
formance of the air conditioner and damage the com-
pressor. Moisture will boil at near room temperature
when exposed to vacuum. To evacuate the refrigerant
system:
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 suitable charging station, refrigerant
recovery machine, or a manifold gauge set with vac-
uum pump to the service ports (Fig. 10).
(2) Open the suction and discharge valves and
start the vacuum pump. The vacuum pump should
run a minimum of 45 minutes prior to charge to
eliminate all moisture in system. When the suction
gauge reads -88 kPa (-26 in. Hg) vacuum or greater
for 45 minutes, close all valves and turn off vacuum
pump. If the system fails to reach specified vacuum,
the refrigerant system likely has a leak that must be
corrected. If the refrigerant system maintains speci-
fied vacuum for at least 30 minutes, start the vac-
uum pump, open the suction and discharge valves.
Then allow the system to evacuate an additional 10
minutes.
Fig. 9 Manifold Gauge Set- Typical
NS/GSHEATING AND AIR CONDITIONING 24 - 17
SERVICE PROCEDURES (Continued)

(3) Close all valves. Turn off and disconnect the
vacuum pump.
(4) The refrigerant system is prepared to be
charged with refrigerant.
THERMOCOUPLE PROBE
To diagnose the A/C system, a temperature probe is
required to measure liquid line temperature. The
clamp-on type K probe shown in this manual is avail-
able through the Chrysler Professional Service Equip-
ment (PSE) program. This probe is compatible with
temperature-measuring instruments that accept Type
K Thermocouples and have a miniature connector
input. Other temperature probes are available through
aftermarket sources. All references in this manual will
reflect the use of the probe made available through the
Professional Service Equipment program.
In order to use the temperature probe, a digital
thermometer will be required. If a digital thermo-meter is not available, an adapter is available
through the Professional Service Equipment pro-
gram. It can convert any standard digital multimeter
into a thermometer. This adapter is designed to
accept any standard K-type thermocouple.
If a digital multimeter is not available, it to can be
ordered through Professional Service Equipment pro-
gram.
STICKING HVAC CONTROL MODULE PUSH
BUTTONS
To service HVAC control module push buttons that
are sticking, spray between the buttons with Mopart
MP-50. The MP-50 is a all purpose lubricant for
mechanical and electrical uses. After spraying around
the push buttons wipe any excess off the radio bezel
and HVAC control module push buttons. Operate the
buttons to ensure that they are operating freely.
Fig. 10 Refrigerant Lines and Port Locations (2.5L Turbo Diesel engine)
24 - 18 HEATING AND AIR CONDITIONINGNS/GS
SERVICE PROCEDURES (Continued)