1996 CHRYSLER VOYAGER light

(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)

(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)

(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)

INSTALLATION
For installation, reverse the above procedures.
Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tighten
heater core tube retaining plate to 361 N´m (276
9 in. lbs.) torque.
HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings
before proceeding with this operation.
(1) Drain engine cooling system. Refer to Group 7,
Engine Cooling.
(2) Loosen clamps at each end of heater hose to be
removed (Fig. 38) and (Fig. 39).
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 ground wire at dash panel.
(4) Remove the nut retaining the refrigerant line
sealing plate to the expansion valve (Fig. 27).
(5) Remove the stud from the expansion valve (Fig.
28).
(6) Remove liquid line from expansion valve.
(7) Cover the openings to prevent contamination.
(8) Disconnect wire connector at pressure trans-
ducer.
(9) Remove liquid line mounting clip at right strut
tower.
(10) Using access slot between radiator crossmem-
ber and grille, loosen liquid line mounting plate at
filter-drier. Remove liquid line from filter-drier.
(11) 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.
²Assemble line halves after it is installed on vehi-
cle.
²Evacuate and recharge A/C system.
Fig. 37 Brake Pedal
Fig. 38 Upper Heater Hose
Fig. 39 Lower Heater Hose
24 - 28 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)