1996 CHRYSLER VOYAGER steering

(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)

(3) Install hood latch cable.
(4) Install lower steering column cover and knee
blocker reinforcement.
JACK STORAGE COVER
LONG WHEEL BASE
REMOVAL
(1) Depress latch handle at top of jack storage
cover (Fig. 50).
(2) Pull outward at top of cover to disengage latch.
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Place jack storage cover in position on vehicle.
(2) Align guide pins.
(3) Push inward at top of cover to engage latch
and fastener.
SHORT WHEEL BASE
REMOVAL
(1) Open quarter panel bin storage cover.
(2) Lift upward and rearward on jack storage cover
retaining latch to disengage (Fig. 51).
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Position jack storage cover to vehicle.
(2) Snap storage cover latch into position on quar-
ter trim panel.
(3) Close quarter trim panel bin storage cover.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second rear seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt holding second rear seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Remove jack storage cover.
(6) Remove screws holding trim panel to D-pillar
(Fig. 52), (Fig. 53), and (Fig. 54).
(7) Disengage hidden clips holding trim to D-pillar.
(8) Disconnect speaker wire connector, if equipped.
(9) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(10) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
Fig. 49 Hood Release Handle
Fig. 50 Jack Storage Cover ± LWB
Fig. 51 Jack Storage Cover ± SWB
NSBODY 23 - 43
REMOVAL AND INSTALLATION (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)

(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)

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.
(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.
Fig. 11 A/C Pressure Transducer Removal
Fig. 12 Side View Of HVAC With Actuators
Fig. 13 ABS Control Module
Fig. 14 Blend-Air Actuator
24 - 20 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Remove resistor block by inserting a flat blade
pry tool on the side of the resistor block and pushing
inward. Two guide lines are shown on the right hand
edge of the resistor block to help guide the blade
position. This will release the clips on the side of the
resistor block. Pull resistor block out.
INSTALLATION
For installation, reverse the above procedures.
Make sure the ªTOPº lettering is on the top of the
resistor. The coils on the Resistor Block should not be
contacting one another. Before installation, gently
separate the coils (with fingers only) if one coil is
contacting another.
BLOWER MOTOR WHEEL
The blower motor wheel is not serviced separately.
If the wheel needs to be replaced it is serviced as an
assembly of the blower motor. For service procedure
information, refer to Blower Motor Replacement in
this group.
COMPRESSOR (2.5L TURBO DIESEL)
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) Reclaim refrigerant.
(3) Raise vehicle on hoist.
(4) Remove refrigerant lines from compressor and
cap all lines (Fig. 10).
(5) Remove flex drive bolts from behind the power
steering pump (Fig. 20).
(6) Remove compressor mounting bolts (Fig. 20).
(7) pry compressor off of the dowel pins and
remove compressor.
INSTALLATION
(1) Transfer mounting spacer/bushings onto the
new compressor.
(2) Lift compressor into place and start compressor
mounting bolts. Do not tighten bolts at this time. The
compressor may have to be moved slightly to align
the flex drive bolts.
(3) Align compressor clutch with flex drive. Then
start both flex drive bolts. Tighten the bolts after
both flex drive bolts have been installed.
(4) Tighten compressor mounting bolts.
(5) Lower vehicle and install refrigerant lines.
Always replace O-rings and gaskets.
(6) Evacuate refrigerant system. Charge system
with the correct amount of R-134a refrigerant. The
refrigerant capacity is .91 kg.67 gm. (32 oz.62.0
oz.).
24 - 22 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)