2001 CHRYSLER VOYAGER Service Manual

low oil pressure check engine tire pressure reset oil level remove seats brake fluid

Page 3681 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required (Fig. 12).
(2) Slide the floor distribution duct assembly
under the instrum

INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required (Fig. 12).
(2) Slide the floor distribution duct assembly
under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.
(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Disconnect the liquid line and suction line from
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(5) Disconnect the heater hoses from the heater
core tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(6) Remove the four nuts that secure the heater-
A/C unit housing studs to the engine compartment
side of the dash panel (Fig. 13).
(7) Remove the instrument panel from the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(8) Remove the floor distribution duct from the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - REMOVAL).
(9) Remove the one screw that secures the heater-
A/C unit housing bracket to the passenger compart-
ment side of the dash panel (Fig. 14).
(10) Pull the heater-A/C unit housing rearward far
enough for the mounting studs to clear the dash
panel and remove the unit from the passenger com-
partment.
Fig. 12 Floor Distribution Ducts
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-51
FLOOR DISTRIBUTION DUCTS (Continued)

Page 3682 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
(1) Position the heater-A/C unit housing against
the dash panel in the passenger compartment with
the four mounting studs located in their proper
mounting holes in the dash panel (Fig. 14

INSTALLATION
(1) Position the heater-A/C unit housing against
the dash panel in the passenger compartment with
the four mounting studs located in their proper
mounting holes in the dash panel (Fig. 14).
(2) Install and tighten the one screw that secures
the heater-A/C unit housing bracket to the passenger
compartment side of the dash panel. Tighten the
screw to 3 N´m (26 in. lbs.).
(3) Install and tighten the four nuts that secure
the heater-A/C unit housing studs to the engine com-partment side of the dash panel (Fig. 13). Tighten
the nuts to 7 N´m (62 in. lbs.).
(4) Reinstall the floor distribution duct onto the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - INSTALLATION).
(5) Reinstall the instrument panel into the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
INSTALLATION).
(6) Reconnect the heater hoses to the heater core
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(7) Reconnect the suction line and liquid line to
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(8) Reconnect the battery negative cable.
(9) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(10) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
PANEL DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
Fig. 13 Heater-A/C Unit Housing Studs
1 - HEATER-A/C UNIT HOUSING
2 - DASH PANEL
3 - NUT (4)
4 - STUD (4)
Fig. 14 Heater-A/C Unit Housing
1 - HEATER-A/C UNIT HOUSING
2 - SCREW
3 - BRACKET
4 - DASH PANEL
24 - 52 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

Page 3683 of 4284

CHRYSLER VOYAGER 2001 Service Manual (2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be c

Page 3684 of 4284

CHRYSLER VOYAGER 2001 Service Manual DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION...........................54
REMOVAL..............................54
INSTALLATION...........................54
A/C DISTRIBUTION

DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION...........................54
REMOVAL..............................54
INSTALLATION...........................54
A/C DISTRIBUTION DUCT
REMOVAL..............................55
INSTALLATION...........................55
BLOWER MOTOR
DESCRIPTION...........................55
OPERATION.............................55DIAGNOSIS AND TESTING.................56
BLOWER MOTOR......................56
REMOVAL..............................58
INSTALLATION...........................58
REAR HEATER-A/C HOUSING
REMOVAL..............................58
INSTALLATION...........................60
REAR HEATER DISTRIBUTION DUCT
REMOVAL..............................61
INSTALLATION...........................61
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear heater-A/C unit housing through
one or a combination of the two main housing out-
lets: air conditioner, or heater. Once the conditioned
air exits the unit housing, it is directed through
molded plastic ducts to the various outlets in the
vehicle interior. These outlets and their locations are
as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear heater distribution duct to the intermediate and
rear seat occupants. The floor outlets are integral to
the right quarter trim panel and, if faulty or dam-
aged, the quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear A/C distribution
duct and the headliner ducts to the intermediate and
rear seat occupants. The headliner ducts are integral
to the headliner panel. Each overhead outlet is
housed in a headliner bezel. The two forward head-
liner bezels also feature a courtesy lamp, a fold-away
coat hook, and a fold-away assist handle. The over-
head outlets can be removed from the headliner
bezels individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel (Fig. 1).
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
24 - 54 DISTRIBUTION - REARRS

Page 3685 of 4284

CHRYSLER VOYAGER 2001 Service Manual A/C DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear air

A/C DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear air conditioning distribution duct
upwards far enough to disengage it from the outlet at
the top of the rear heater-A/C unit housing (Fig. 2).
(3) While pulling the lower end of the auxiliary air
conditioning distribution duct away from the rear
heater-A/C unit outlet, disengage the upper end of
the distribution duct from the headliner duct.
(4) Remove the auxiliary air conditioning distribu-
tion duct from the vehicle.
INSTALLATION
(1) Align the upper end of the rear air conditioning
distribution duct to the headliner duct (Fig. 2).
(2) Slide the upper end of the rear air conditioning
distribution duct onto the headliner duct far enough
to align the lower end of the duct with the outlet at
the top of the rear heater-A/C unit housing.
(3) Slide the rear air conditioning distribution duct
downwards far enough to engage it onto the outlet at
the top of the rear heater-A/C unit housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 3). The
blower motor and wheel are located in a housing
near the top of the rear heater-A/C unit in the pas-
senger compartment behind the right rear wheel
house. The rear heater-A/C unit housing must be
removed from the vehicle to access the blower motor
and blower wheel for service. The blower motor and
blower motor wheel are a factory balanced unit and
cannot be adjusted or repaired. If faulty or damaged,
the blower motor and blower wheel must be replaced
as a unit.
OPERATION
The rear blower motor will operate whenever the
ignition switch is in the On position, the heater-A/C
control power is turned on, and the rear heater-A/C
Fig. 2 Rear A/C Distribution Duct
1 - HEADLINER DUCT
2 - REAR A/C DISTRIBUTION DUCT
3 - REAR HEATER-A/C UNIT OUTLET
Fig. 3 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
RSDISTRIBUTION - REAR24-55

Page 3686 of 4284

CHRYSLER VOYAGER 2001 Service Manual system control switch on the front heater-A/C control
is not in the Off position. The blower motor can only
be turned off by turning off the rear system at the
front heater-A/C control. The blower mot

system control switch on the front heater-A/C control
is not in the Off position. The blower motor can only
be turned off by turning off the rear system at the
front heater-A/C control. The blower motor receives
battery current whenever the rear blower motor
relay is energized. The rear blower motor relay out-
put circuit is protected by a fuse in the Intelligent
Power Module (IPM) located in the engine compart-
ment near the battery. In the MTC system, the
blower motor speed is controlled by regulating the
path to ground through the blower control switch and
the blower motor resistor. In the ATC system, the
blower motor speed is controlled by an electronic
blower power module, which uses a pulse width mod-
ulated input from the ATC module and feedback from
the blower motor to regulate the blower motor
ground path it provides. The blower motor and wheel
are used to control the velocity of air moving through
the rear heater-A/C unit housing. The blower motor
controls the velocity of the air flowing through the
rear heater-A/C housing by spinning the blower
wheel within the housing at the selected speed or, in
the ATC system, at the selected or programmed
speed.
DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR
BLOWER MOTOR INOPERATIVE
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Intelligent Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Turn the ignition switch to the On position. Be
certain that the rear heater-A/C control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, proceed to diagnosis of the rear blower
motor relay. (Refer to 24 - HEATING & AIR CONDI-TIONING/CONTROLS - REAR/BLOWER MOTOR
RELAY - DIAGNOSIS AND TESTING).
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector for
the rear blower motor resistor (Manual Temperature
Control) or the rear blower power module (Automatic
Temperature Control) from the resistor or module
connector receptacle. Reconnect the battery negative
cable. Turn the ignition switch to the On position. Be
certain that the rear heater-A/C control power is
turned on. Check for battery voltage at the fused
rear blower motor relay output circuit cavity of the
rear HVAC wire harness connector for the rear
blower motor resistor (MTC) or the rear blower
power module (ATC). If OK, go to Step 4. If not OK,
repair the open fused front blower motor relay output
circuit to the IPM as required.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear blower motor pigtail wire connec-
tor from the take out and connector of the rear
HVAC wire harness (MTC) or the connector recepta-
cle of the rear blower power module (ATC). Use
jumper wires to connect a battery and ground feeds
to the blower motor pigtail wire connector. The
blower motor should operate. If OK with MTC, pro-
ceed to diagnosis of the rear blower motor resistor.
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS - REAR/BLOWER MOTOR RESISTOR -
DIAGNOSIS AND TESTING). If OK with ATC, use a
DRBIII scan tool to diagnose the rear blower power
module. Refer to the appropriate diagnostic informa-
tion. If not OK with MTC or ATC, replace the faulty
rear blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart (Fig. 4).
24 - 56 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

Page 3687 of 4284

CHRYSLER VOYAGER 2001 Service Manual Fig. 4 Blower Motor Noise/Vibration Diagnosis
RSDISTRIBUTION - REAR24-57
BLOWER MOTOR (Continued)

Page 3688 of 4284

CHRYSLER VOYAGER 2001 Service Manual REMOVAL
The rear blower motor and blower wheel are ser-
viced only as a balanced unit. If either component is
faulty or damaged, the entire unit must be replaced.
WARNING: REFER TO THE APPLICABLE WARN

REMOVAL
The rear blower motor and blower wheel are ser-
viced only as a balanced unit. If either component is
faulty or damaged, the entire unit must be replaced.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Remove the rear heater-A/C unit housing from
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(3) Remove the three screws that secure the
blower motor to the outboard side of the rear heater-
A/C unit housing (Fig. 5).
(4) Remove the blower motor and blower wheel
from the rear heater-A/C unit housing.
INSTALLATION
(1) Position the blower motor and blower wheel
onto the outboard side of the rear heater-A/C unit
housing (Fig. 5).
(2) Install and tighten the three screws that secure
the blower motor to the rear heater-A/C unit housing.
Tighten the screws to 2 N´m (18 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(4) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
REAR HEATER-A/C HOUSING
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
Fig. 5 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

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