1996 CHRYSLER VOYAGER wiring

(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)

²Install two-piece line in place of original part.
²Assemble line halves after it is installed on vehi-
cle.
²Evacuate and recharge A/C system.
RECIRC DOOR ACTUATOR
REMOVAL
(1) Pull back on carpeting on the right lower floor.
(2) Remove Recirc. door actuator connector.
(3) Remove (3) mounting screws for Recirc. actua-
tor (Fig. 62).
(4) Remove Recirc. actuator.
(5) Disengage actuator linkage at Recirc. door.
(6) Remove actuator from vehicle.
INSTALLATION
(1) For installation, reverse the above procedures.
(2) Perform the HVAC control Calibration Diagnos-
tic and Cooldown test.
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION
Heater A/C Housing must be removed from vehicle
before performing this operation. Refer to Heater A/C
Unit HousingÐRemoval and Installation.
DISASSEMBLYÐEVAPORATOR HOUSING
(1) Place HVAC unit assembly on workbench.
(2) Remove distribution housing mounting screws
(Fig. 63).
(3) Remove blower motor cover (Fig. 64).
(4) Remove blower motor wiring grommet and feed
wiring through blower housing (Fig. 65).
(5) Remove blower motor screws. Remove blower
motor from housing (Fig. 66) and (Fig. 67).
(6) Remove recirculation door cover (Fig. 68).(7) Remove Recirc. door (Fig. 69).
(8) Remove screws around the perimeter of the
upper HVAC housing (Fig. 70).
Fig. 62 Recirculation Door Actuator
Fig. 63 Distribution Housing
Fig. 64 Blower Motor Cover
Fig. 65 Blower Motor Grommet
24 - 34 HEATING AND AIR CONDITIONINGNS
REMOVAL AND INSTALLATION (Continued)

DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When diagnosing electrical problems in the auxil-
iary rear heater or rear A/C system, refer to Group
8W, Wiring Diagrams.
When diagnosing problems in the auxiliary sys-
tems, refer to diagnostic sections for front heater A/C.
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT-A/C
REMOVAL
(1) Remove quarter trim panel, D-pillar, and head-
liner (Fig. 8). Refer to Group 23, Body.
(2) Remove screws securing D-pillar duct to quar-
ter panel. Pull duct up and away from unit.
(3) Remove screws securing duct to rear header
(Fig. 9).
(4) Remove screws securing duct to right and left
rails (Fig. 10).
INSTALLATION
For installation, reverse the above procedures.
AIR DISTRIBUTION DUCT-HEATER
REMOVAL
(1) Remove quarter trim panel and D-pillar (Fig.
8) and (Fig. 11). Refer to Group 23, Body.
(2) Remove screws securing lower heat duct to
housing.
INSTALLATION
For installation, reverse the above procedures.
Fig. 7 Rear Blower Switch
Fig. 8 Quarter Trim Panel
Fig. 9 Rear Crossover Duct
Fig. 10 Upper A/C Duct
NSHEATING AND AIR CONDITIONING 24 - 43
DESCRIPTION AND OPERATION (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)

(8) Pinch off heater lines at heater core hookup
(Fig. 20).
(9) Remove heater hoses at heater core (Fig. 21).(10) Remove quarter trim panel mounting bracket
(Fig. 22).
(11) Remove blower motor wiring harness connec-
tor.
(12) Remove rear upper duct trim screw (Fig. 23).
(13) Remove (2) Heater-A/C housing mounting
bolts (Fig. 24).
(14) Pull up on upper A/C duct. Tilt A/C unit out-
ward (Fig. 25).
(15) Lift the unit enough to clear floor pan.
Remove unit from the vehicle.
INSTALLATION
For installation, reverse the above procedures.
Install new O-rings at refrigerant lines. Evacuate
and charge the refrigerant system. Fill the heater
core (Fig. 26). Test for leaks and overall performance.
Fig. 19 Lower Heater Duct
Fig. 20 Heater Core Lines
Fig. 21 Heater Hoses
Fig. 22 Trim Panel Mounting Bracket
Fig. 23 Upper Duct Trim
NSHEATING AND AIR CONDITIONING 24 - 47
REMOVAL AND INSTALLATION (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)

²Set A/C to ON, if A/C Clutch does not engage
make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or
the wiring repair needs to be completed. Then, press
and hold the intermittent wipe button for 5 seconds.
²Run Diagnostics (Depress REAR WIPER and
REAR WASH)
²When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows:
²REAR WIPER LED will display the Level
²INTERMITTENT LED will display ten's digit
²Short Pause
²INTERMITTENT LED will display the one's
digit.
The HVAC control module will continue to cycle
the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cooldown
test is exited.
HVAC CONTROL DIAGNOSTIC CONDITIONS
For wiring circuits, wiring connectors, and Pin
numbers, refer to Group 8W, Wiring Diagrams.
After calibration, Rear Wiper LED flashing
once, Intermittent LED not flashing.
The system has passed calibration. Press the Rear
Wiper button to exit calibration.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing once. The
mode actuator did not reach defrost position.
(1) Using a voltmeter, check the mode door actua-
tor wiring connector. Check Pin 1 for battery voltage.
Move the HVAC control from the defrost to panel
position, and check Pin 6 voltage it should change
from 0.5 - 1 volts to 3.5 - 4.5 volts. If voltage is OK,
go to Step 2. If not OK, check for loose or corroded
connector, open or shorted circuit and repair as nec-
essary.
(2) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 3. If not OK, repair as necessary.
(3) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(4) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing twice. The
mode actuator did not reach panel position.
(1) Using a voltmeter, check the mode door actua-
tor wiring connector. Check Pin 1 for battery voltage.
Move the HVAC control from panel to defrost posi-
tion, and check Pin 6 voltage it should change from
3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is OK, go toStep 2. If not OK, check for loose or corroded connec-
tor, open or shorted circuit and repair as necessary.
(2) Remove actuator, and check if the gear pins are
in the correct cam track or binding. If OK, go to Step
3. If not OK, repair as necessary.
(3) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(4) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing three times.
The main temperature actuator/passenger
temperature actuator on a zone system did
not reach cold stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check the temperature door
actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from the cold to hot
position, and check Pin 5 voltage it should change
from 0.5 - 4 volts to 3.5 - 4.5 volts. If voltage is OK,
go to Step 3. If not OK, check for loose or corroded
connector, open or shorted circuit and repair as nec-
essary.
(3) Remove actuator, and check if gear pins are in
the correct cam track or binding. If OK, go to Step 4.
If not OK, repair as necessary.
(4) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing four times.
The main temperature actuator/passenger
temperature actuator on a zone system did
not reach hot stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check the temperature door
actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from hot to cold
position and check Pin 5 voltage it should change
from 3.5 -4.5 volts 0.5 - 1.5 volts. If voltage is OK, go
to Step 3. If not OK, check for loose or corroded con-
nector, open or shorted circuit and repair as neces-
sary.
(3) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 4. If not OK, repair as necessary.
NS/GSHEATING AND AIR CONDITIONING 24 - 9
DIAGNOSIS AND TESTING (Continued)

(4) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing five times.
The evaporator probe is open.
(1) Using a voltmeter, check Pin 1 of the evapora-
tor probe wiring connector for 0.1 - 4.75 volts. If OK,
go to Step 2. If not OK, if greater than 4.75 volts
check for loose or corroded connector, open circuit
and repair as necessary.
(2) Using a ohmmeter, check Pin 2 for a good
ground, If OK, go to Step 3. If not OK, check for loose
or corroded connector, open or shorted circuit and
repair as necessary.
(3) If ground and power circuit are OK, replace
Evaporator Probe.
(4) Once repairs are completed, press the intermit-
tent button about 5 seconds until all LED's light to
remove fault code from memory. Then repeat the Cal-
ibration Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing six times. The
evaporator probe is shorted.
(1) Using a voltmeter, check Pin 1 of the evapora-
tor probe wiring connector for 0.1 - 4.75 volts. If OK,
go to Step 2. If less than 0.1 volts, check for loose or
corroded connector, open or shorted circuit and repair
as necessary.
(2) Using a ohmmeter, check Pin 2 for a good
ground, If OK, go to Step 3. If not OK, check for
shorted circuit and repair as necessary.
(3) If ground and power circuit are OK, replace
Evaporator Probe
(4) Once repairs are completed, press the intermit-
tent button about 5 seconds until all LED's light to
remove fault code from memory. Then repeat the Cal-
ibration Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing seven times.
The Driver's temperature actuator on a zone
system did not reach cold stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check at the temperature
door actuator wiring connector, check Pin 1 for bat-
tery voltage. Move the HVAC control from cold to the
hot position, check Pin 4 voltage it should change
from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, goto Step 3. If not OK, check for loose or corroded con-
nector, open or shorted circuit and repair as neces-
sary.
(3) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 4. If not OK, repair as necessary.
(4) Check for binding doors, if door are binding
repair as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing eight times.
The Driver's temperature actuator on a zone
system did not reach hot stop.
(1) Check if the correct HVAC control module was
used.
(2) Using a voltmeter, check at the temperature
door actuator wiring connector, check Pin 1 for bat-
tery voltage. Move the HVAC control from hot to cold
position, Pin 4 voltage it should change from 3.5 - 4.5
volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3.
If not OK, check for loose or corroded connector, open
or shorted circuit and repair as necessary.
(3) Remove actuator, and check if the gear pins are
in the correct track on cam or if they are binding. If
OK, go to Step 4. If not OK, repair as necessary.
(4) Check for binding door, if door is binding repair
as necessary. If gears and door are OK, replace
actuator.
(5) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing
once, Intermittent LED flashing nine times.
The HVAC control module, has a internal
failure.
(1) Replace the HVAC control module.
(2) Once repairs are completed repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
After calibration and testing the A/C and
RECIRC LED flashing simultaneously. Failed
Cooldown test.
(1) Determine if the refrigerant system is operat-
ing correctly:
²Check the outlet air temperature
²Feel the compressor suction plumbing, is it hot?
(2) If not OK, go to Step 3. If OK, repeat the Cal-
ibration Diagnostic and Cooldown test.
(3) If system does not seem to be operating cor-
rectly, perform diagnostics for poor performance:
²Low refrigerant charge
24 - 10 HEATING AND AIR CONDITIONINGNS/GS
DIAGNOSIS AND TESTING (Continued)