1996 CHRYSLER VOYAGER service

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)

(4) Remove grommet for wiring (Fig. 16). Feed wir-
ing through blower housing (Fig. 17).
(5) Remove mounting screws for blower motor (Fig.
18).(6) Allow the blower assembly to drop down, and
remove assembly from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BLOWER MOTOR RESISTOR BLOCK
REMOVAL
(1) Open hood.
(2) Locate and remove the wire connector from the
blower resistor block. Block is located at the back of
the engine compartment on the passenger side of the
vehicle under the wiper module (Fig. 19).
NOTE: It is not necessary to remove the wiper
module to access the resistor block.
WARNING: THE RESISTOR BLOCK MAY BE HOT.
DO NOT ATTEMPT TO SERVICE THE RESISTOR
BLOCK IF THE SYSTEM HAS BEEN RUNNING
RECENTLY. LET THE SYSTEM COOL DOWN
BEFORE REPAIRS ARE INITIATED.
Fig. 15 Blower Motor Cover
Fig. 16 Wiring Grommet
Fig. 17 Feeding Wiring Through Housing
Fig. 18 Blower Motor Screws
Fig. 19 Resistor Block Removal
NS/GSHEATING AND AIR CONDITIONING 24 - 21
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)

(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.
(2) Remove liquid line at filter-drier (Fig. 21).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Drain engine coolant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
Installation procedures. Plug coolant lines.(6) Remove suction and liquid lines at the expan-
sion valve (Fig. 27).
(7) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Systems.
(8) Remove heater ducts.
(9) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(10) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 30).
(11) Disconnect the HVAC housing wiring harness.
(12) 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.
31).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 32).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 33)
(7) Pinch off heater lines under the hood.
Fig. 30 HVAC Bolt-Up
24 - 26 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)

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. 40).
(3) Remove mode actuator connector (Fig. 41).
(4) Remove mode door actuator (Fig. 42).
INSTALLATION
(1) For installation, reverse the above procedures.
(2) Perform the HVAC control Calibration Diagnos-
tic and Cooldown test.
SIDE WINDOW DEMISTER DUCTS
LEFT SIDE
The LEFT side window demister duct is a two
piece design. The left side has a long duct that
attaches to an intermediate duct and then to the dis-tribution housing. The duct is located on top of the
instrument panel. To service the duct, remove the I/P
cover and remove duct retainers/fasteners. (Fig. 43).
RIGHT SIDE
The demister duct on the right side is a one piece
design. It is one long duct that attaches to the distri-
bution housing. The duct is located on top of the
instrument panel and it is not serviceable (Fig. 44).
SUCTION 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 suction line from expansion valve.
Fig. 40 ABS Control Module
Fig. 41 Mode Door Actuator Connector
Fig. 42 Mode Door Actuator
Fig. 43 Left Side Demister Duct
NS/GSHEATING AND AIR CONDITIONING 24 - 29
REMOVAL AND INSTALLATION (Continued)

EVAPORATIVE EMISSION CONTROLS
INDEX
page page
DESCRIPTION AND OPERATION
CRANKCASE VENT FILTER................ 16
EVAPORATION CONTROL SYSTEM......... 13
EVAPORATIVE (EVAP) CANISTER........... 13
LEAK DETECTION PUMP................. 14
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEMS............................ 15
PRESSURE-VACUUM FILLER CAP.......... 14
PROPORTIONAL PURGE SOLENOID......... 13ROLLOVER VALVE....................... 13
VEHICLE EMISSION CONTROL INFORMATION
LABEL............................... 16
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP................. 16
PCV VALVE TEST....................... 16
REMOVAL AND INSTALLATION
LEAK DETECTION PUMP REPLACEMENT.... 16
ROLLOVER VALVES..................... 17
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
The evaporation control system prevents the emis-
sion of fuel tank vapors into the atmosphere. When
fuel evaporates in the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal filled evap-
orative canister. The canister temporarily holds the
vapors. The Powertrain Control Module (PCM) allows
intake manifold vacuum to draw vapors into the com-
bustion chambers during certain operating condi-
tions.
All engines use a duty cycle purge system. The
PCM controls vapor flow by operating the duty cycle
EVAP purge solenoid. Refer to Duty Cycle EVAP
Purge Solenoid in this section.
NOTE: The evaporative system uses specially man-
ufactured hoses. If they need replacement, only use
fuel resistant hose.
ROLLOVER VALVE
All vehicles have a rollover valve. The valve also
prevents fuel flow through the fuel tank vent valve
hoses should the vehicle rollover. All vehicles pass a
360É rollover.
The charcoal filled evaporative canister stores the
vapors. The rollover valve is not a serviceable item.
EVAPORATIVE (EVAP) CANISTER
All vehicles use a sealed, maintenance free, evapo-
rative (charcoal) canister. The canister is attached to
the frame under the driver's seat (Fig. 1).
Fuel tank vapor vents into the canister. The canis-
ter temporarily holds the fuel vapors until intake
manifold vacuum draws them into the combustion
chamber. The canister proportional purge solenoidallows the canister to be purged at predetermined
intervals and engine conditions.
PROPORTIONAL PURGE SOLENOID
All vehicles use a Proportional purge solenoid. The
solenoid regulates the rate of vapor flow from the
EVAP canister to the throttle body. The PCM oper-
ates the solenoid.
During the cold start warm-up period and the hot
start time delay, the PCM does not energize the sole-
noid. When de-energized, no vapors are purged. The
PCM de-energizes the solenoid during open loop oper-
ation.
Fig. 1 Evaporative Canister
NSEMISSION CONTROL SYSTEMS 25 - 13

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
GENERAL INFORMATION................. 18
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST................... 20
EGR SYSTEM ON-BOARD DIAGNOSTICS..... 19
EGR SYSTEM TEST..................... 19
EGR VALVE CONTROL (TRANSDUCER) TEST . 21
EGR VALVE LEAKAGE TEST............... 20REMOVAL AND INSTALLATION
EGR TUBE SERVICEÐ3.0L ENGINES........ 22
EGR TUBE SERVICEÐ3.3/3.8L ENGINES..... 22
EGR VALVE SERVICEÐ3.0L ENGINES....... 21
EGR VALVE SERVICEÐ3.3/3.8L ENGINES.... 22
SPECIAL TOOLS
EMISSION CONTROL SYSTEM............. 23
DESCRIPTION AND OPERATION
GENERAL INFORMATION
Refer to Monitored Systems - EGR Monitor in this
group for more information.
The 3.0, 3.3, and 3.8L engines use Exhaust Gas
Recirculation (EGR) systems (Fig. 1) and (Fig. 2).
The EGR system reduces oxides of nitrogen (NOx) in
engine exhaust and helps prevent spark knock. The
system allows a predetermined amount of hot
exhaust gas to recirculate and dilute the incoming
air/fuel mixture. The diluted air/fuel mixture reduces
peak flame temperature during combustion.
The EGR system consists of:
²EGR tube (connects a passage in the intake
manifold to the exhaust manifold)
²EGR valve
²Electronic EGR Transducer
²Connecting hoses
The Electronic EGR Transducer contains an elec-
trically operated solenoid and a back-pressure trans-ducer (Fig. 3). The PCM operates the solenoid. The
PCM determines when to energize the solenoid.
Exhaust system back-pressure controls the trans-
ducer.
When the PCM energizes the solenoid, vacuum
does not reach the transducer. Vacuum flows to the
transducer when the PCM de-energizes the solenoid.
When exhaust system back-pressure becomes high
enough, it fully closes a bleed valve in the trans-
ducer. When the PCM de-energizes the solenoid and
back-pressure closes the transducer bleed valve, vac-
uum flows through the transducer to operate the
EGR valve.
De-energizing the solenoid, but not fully closing the
transducer bleed hole (because of low back-pressure),
varies the strength of vacuum applied to the EGR
valve. Varying the strength of the vacuum changes
Fig. 1 EGR MountingÐ3.0L Engine
Fig. 2 EGR MountingÐ3.3/3.8L Engines
25 - 18 EMISSION CONTROL SYSTEMSNS

the amount of EGR supplied to the engine. This pro-
vides the correct amount of exhaust gas recirculation
for different operating conditions.
This system does not allow EGR at idle. The EGR
systems can operate at all coolant temperatures
above 60ÉF as long as the battery ambient tempera-
ture is above 7ÉF.
DIAGNOSIS AND TESTING
EGR SYSTEM ON-BOARD DIAGNOSTICS
The PCM performs an on-board diagnostic check of
the EGR system. The diagnostic system uses the
electronic EGR transducer for the system tests.
The diagnostic check activates only during selected
engine/driving conditions. When the conditions are
met, the PCM energizes the transducer solenoid to
disable the EGR. The PCM checks for a change in
the heated oxygen sensor signal. If the air-fuel mix-
ture goes lean, the PCM will attempt to enrichen the
mixture. The PCM registers a Diagnostic Trouble
Code (DTC) if the EGR system is not operating cor-
rectly. After registering a DTC, the PCM turns on the
malfunction indicator (Check Engine) lamp after 2
consecutive trips. There are 2 types of failures sensed
by the PCM. The first is a short or open in the elec-
trical solenoid circuit. The second is a mechanical
failure or loss of vacuum. The Malfunction Indicator
Lamp (MIL) indicates the need for service.
If a problem is indicated by the MIL and a DTC for
the EGR system is set, check for proper operation of
the EGR system. Use the System Test, EGR Gas
Flow Test. If the EGR system tests properly, check
the system using the DRB scan tool. Refer to
On-Board Diagnosis sections in this Group. Also,
refer to the DRB scan tool and the appropriate Pow-
ertrain Diagnostics Procedure manual.
EGR SYSTEM TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE TESTING THE EGR SYS-
TEM.
(1) Check the condition of all EGR system hoses
and tubes for leaks, cracks, kinks and hardening of
rubber hoses. Repair and correct these conditions
before performing any tests.
(2) Be sure the hoses at both the EGR valve and
EGR valve control are connected to the proper fit-
tings (Fig. 4).
(3) Be sure the electrical connector is firmly con-
nected at the valve control.
(4) To check EGR system operation, connect the
DRB scan tool to the 16±way data link connector.
The data link connector is located on the lower edge
of the instrument panel near the steering column.
Refer to the appropriate Powertrain Diagnostic Pro-
cedures service manual for operation of the DRB
scan tool when diagnosing the EGR system.
(5) After checking the system with the DRB scan
tool, proceed to the following EGR Valve Leakage and
EGR Valve Control Tests and repair as necessary.
Fig. 3 Electric EGR Transducer Assembly
Fig. 4 EGR Value and EGR Value ÐTypical
NSEMISSION CONTROL SYSTEMS 25 - 19
DESCRIPTION AND OPERATION (Continued)