2004 CHRYSLER VOYAGER Service Manual

heating run flat handbrake radio oil reset change time

Page 2417 of 2585

CHRYSLER VOYAGER 2004 Service Manual erence signal and a sensor ground to the transducer,
then monitors the output voltage of the transducer
on a sensor return circuit to determine refrigerant
pressure. The PCM is programmed to respond t

erence signal and a sensor ground to the transducer,
then monitors the output voltage of the transducer
on a sensor return circuit to determine refrigerant
pressure. The PCM is programmed to respond to this
and other sensor inputs by controlling the operation
of the A/C compressor clutch and the radiator cooling
fan to help optimize air conditioning system perfor-
mance and to protect the system components from
damage. The A/C pressure transducer input to the
PCM will also prevent the A/C compressor clutch
from engaging when ambient temperatures are below
about 4.5É C (40É F) due to the pressure/temperature
relationship of the refrigerant. The Schrader-type
valve in the liquid line fitting permits the A/C pres-
sure transducer to be removed or installed without
disturbing the refrigerant in the system. The A/C
pressure transducer is diagnosed using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
The A/C pressure transducer is tested using a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information. Before testing the A/C pressure
transducer, be certain that the transducer wire har-
ness connection is clean of corrosion and properly
connected. For the A/C to operate, an A/C pressure
transducer voltage reading between 0.451 and 4.519
volts is required. Voltages outside this range indicate
a low or high refrigerant system pressure condition
to the powertrain control module (PCM). The PCM is
programmed to respond to a low or high refrigerant
system pressure by suppressing operation of the A/C
compressor. Refer to the A/C Pressure Transducer
Voltage chart for the possible conditions indicated by
the transducer voltage reading.
A/C PRESSURE TRANSDUCER VOLTAGE
Voltage Possible Indication
0.0 1. No sensor supply voltage from
PCM.
2. Shorted sensor circuit.
3. Faulty transducer.
0.150 TO 0.450 1. Ambient temperature below 10É
C (50É F).
2. Low refrigerant system pressure.
0.451 TO 4.519 1. Normal refrigerant system
pressure.
4.520 TO 4.850 1. High refrigerant system pressure.
5.0 1. Open sensor circuit.
2. Faulty transducer.
REMOVAL
NOTE: Note: It is not necessary to discharge the
refrigerant system to replace the A/C pressure
transducer.
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 10).
(3) Remove the A/C pressure transducer from the
fitting on the liquid line.
(4) Remove the O-ring seal from the A/C pressure
transducer fitting and discard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C pressure transducer.
(1) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the A/C pressure
transducer fitting. Use only the specified O-rings as
they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
(2) Install and tighten the A/C pressure transducer
onto the fitting onto the liquid line fitting.
(3) Connect the wire harness connector to the A/C
pressure transducer.
(4) Reconnect the battery negative cable.
Fig. 10 A/C Pressure Transducer - Typical
1 - RIGHT FRONT STRUT TOWER
2 - WIRE HARNESS CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 22 CONTROLS - FRONTRS
A/C PRESSURE TRANSDUCER (Continued)

Page 2418 of 2585

CHRYSLER VOYAGER 2004 Service Manual BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors. Models with the
single zone heater and air conditioner system have a
single blend ai

BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors. Models with the
single zone heater and air conditioner system have a
single blend air door, which is controlled by a single
blend door actuator. Models with the optional dual
zone front heater and air conditioner system have
dual blend air doors, which are controlled by two
blend door actuators. The single zone blend door
actuator is located on the driver's side end of the
HVAC housing, close to the middle of the distribution
housing. In the dual zone system, the same blend
door actuator used for the single zone system
becomes the passenger blend door actuator, and is
mechanically connected to only the passenger side
blend air door. In the dual zone system, a second sep-
arate blend door actuator is also located on the
driver side end of the HVAC housing, close to the
middle of the distribution housing, and is mechani-
cally connected to only the driver's side blend air
door.
The blend door actuators are interchangeable with
each other, as well as with the actuators for the
mode door and the recirculation air door. Each actua-
tor is contained within an identical black molded
plastic housing with an integral wire connector
receptacle. Two integral mounting tabs allow the
actuator to be secured with two screws to the distri-
bution housing. Each actuator also has an identical
output shaft with splines that connects it to the link-
age that drives the proper blend air door. The blend
door actuators do not require mechanical indexing to
the blend door linkage, as they are electronically cal-
ibrated by the heater-A/C control module.
OPERATION
Each blend door actuator is connected to the A/C-
heater control through the vehicle electrical system
by a dedicated two-wire lead and connector from the
HVAC wire harness. The blend door actuator can
move the blend-air door in two directions. When the
A/C-heater control pulls the voltage on one side of
the motor connection high and the other connection
low, the blend-air door will move in one direction.
When the A/C-heater control reverses the polarity of
the voltage to the motor, the blend-air door moves in
the opposite direction. When the A/C-heater control
makes the voltage to both connections high or both
connections low, the blend-air door stops and will not
move. The motor connections also provide a feedback
signal to the A/C-heater control. This feedback signal
allows the A/C-heater control to monitor the opera-
tion and relative positions of the blend door actuator
and the blend-air door. The A/C-heater control learnsthe blend door stop positions during the calibration
procedure and will store a diagnostic trouble code
(DTC) for any problems it detects in the blend door
actuator circuits.
The blend door actuator can be diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures for more information. The blend door actuators
cannot be adjusted or repaired and, if damaged or
faulty, they must be replaced.
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.
NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. The dual zone system has two blend door
actuators, one for the driver side blend air door and
one for the passenger side blend air door. The
same service procedures can be used for each of
these actuators.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the wire harness connector from the
blend door actuator(s) (Fig. 11).
(4) Remove the two screws that secure the blend
door actuator to the distribution housing.
(5) Remove the blend door actuator.
INSTALLATION
(1) Position the blend door actuator onto the distri-
bution housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the blend air door linkage.
(2) Install the two screws that secure the blend
door actuator to the housing. Tighten the screws to 2
N´m (17 in. lbs.).
RSCONTROLS - FRONT24-23

Page 2419 of 2585

CHRYSLER VOYAGER 2004 Service Manual (3) Connect the HVAC wire harness connector to
the blend door actuator.
(4) Install the silencer under the driver side end of
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PAN

(3) Connect the HVAC wire harness connector to
the blend door actuator.
(4) Install the silencer under the driver side end of
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL SILENCER -
INSTALLATION).
(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
BLOWER MOTOR RELAY
DESCRIPTION
The blower motor relay is a International Stan-
dards Organization (ISO) mini-relay (Fig. 12). Relays
conforming to the ISO specifications have common
physical dimensions, current capacities, terminal pat-
terns, and terminal functions. The ISO mini-relay
terminal functions are the same as a conventional
ISO relay. However, the ISO mini-relay terminal pat-
tern (or footprint) is different, the current capacity is
lower, and the physical dimensions are smaller than
those of the conventional ISO relay. The blower
motor relay is located in the Integrated Power Mod-
ule (IPM), which is in the engine compartment near
the battery. See the fuse and relay layout map
molded into the inner surface of the IPM cover for
blower motor relay identification and location.The black, molded plastic case is the most visible
component of the blower motor relay. Five male
spade-type terminals extend from the bottom of the
base to connect the relay to the vehicle electrical sys-
tem, and the ISO designation for each terminal is
molded into the base adjacent to each terminal. The
ISO terminal designations are as follows:
²30 (Common Feed)- This terminal is con-
nected to the movable contact point of the relay.
²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.
²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
The blower motor relay cannot be adjusted or
repaired. If the relay is damaged or faulty, it must be
replaced.
OPERATION
The blower motor relay is an electromechanical
switch that uses a low current input from the Front
Control Module (FCM) to control the high current
output to the blower motor resistor (manual heater-
A/C control) or blower power module (ATC control).
The movable common feed contact point is held
against the fixed normally closed contact point by
spring pressure. When the relay coil is energized, an
electromagnetic field is produced by the coil wind-
ings. This electromagnetic field draws the movable
relay contact point away from the fixed normally
closed contact point, and holds it against the fixed
Fig. 11 Blend Door Actuator - LHD Shown, RHD
Typical
1 - WIRE HARNESS CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)Fig. 12 Blower Motor Relay
24 - 24 CONTROLS - FRONTRS
BLEND DOOR ACTUATOR (Continued)

Page 2420 of 2585

CHRYSLER VOYAGER 2004 Service Manual normally open contact point. When the relay coil is
de-energized, spring pressure returns the movable
contact point back against the fixed normally closed
contact point. The resistor or diode is conne

normally open contact point. When the relay coil is
de-energized, spring pressure returns the movable
contact point back against the fixed normally closed
contact point. The resistor or diode is connected in
parallel with the relay coil in the relay, and helps to
dissipate voltage spikes and electromagnetic interfer-
ence that can be generated as the electromagnetic
field of the relay coil collapses.
The blower motor relay terminals are connected to
the vehicle electrical system through a receptacle in
the Integrated Power Module (IPM). The inputs and
outputs of the blower motor relay include:
²The common feed terminal (30) receives a bat-
tery current input from the battery through a B(+)
circuit at all times.
²The coil ground terminal (85) receives a ground
input through the front/rear blower motor relay con-
trol circuit only when the FCM electronically pulls
the control circuit to ground.
²The coil battery terminal (86) receives a battery
current input from the battery through a B(+) circuit
at all times.
²The normally open terminal (87) provides a bat-
tery current output to the blower motor resistor
(manual heater-A/C control) or blower power module
(automatic heater-A/C control) through a fuse in the
IPM on the fused front blower motor relay output cir-
cuit only when the blower motor relay coil is ener-
gized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the blower motor
relay coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unlatch and remove the cover from the Inte-
grated Power Module (IPM) (Fig. 13).
(3) See the fuse and relay layout map molded into
the inner surface of the IPM cover for front blower
motor relay identification and location.(4) Remove the front blower motor relay from the
IPM by pulling the relay straight up.
INSTALLATION
(1) Refer to the fuse and relay layout map on the
inner surface of the integrated power module (IPM)
cover for front blower motor relay identification and
location.
(2) Position the front blower motor relay to the
proper receptacle in the IPM.
(3) Align the front blower motor relay terminals
with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the front blower motor
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.
(6) Reconnect the negative battery cable.
Fig. 13 Integrated Power Module - Typical
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RSCONTROLS - FRONT24-25
BLOWER MOTOR RELAY (Continued)

Page 2421 of 2585

CHRYSLER VOYAGER 2004 Service Manual BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C system.
Models equipped with the optional Automatic Tem-
perature C

BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C system.
Models equipped with the optional Automatic Tem-
perature Control (ATC) system use a blower power
module, instead of the blower motor resistor block
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/POWER MODULE - DESCRIPTION).
The blower motor resistor block is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The resistor
block consists of a molded plastic mounting plate
with two integral connector receptacles. Concealed
behind the mounting plate are four coiled resistor
wires contained within a protective stamped steel
cage. The blower motor resistor block is accessed for
service by removing the glove box from the instru-
ment panel.
OPERATION
The blower motor resistor block is connected to the
vehicle electrical system through a dedicated take
out and connector of the instrument panel wire har-
ness. A second connector receptacle receives the pig-
tail wire connector from the blower motor. The
blower motor resistor has multiple resistor wires,
each of which will reduce the current flow through
the blower motor to change the blower motor speed.
The blower motor switch in the manual heater-A/C
system directs the ground path for the blower motor
through the correct resistor wire to obtain the
selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through all of the resistor wires. Each higher speed
selected with the blower motor switch applies the
blower motor ground path through fewer of the resis-
tor wires, increasing the blower motor speed.
The blower motor resistor cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR BLOCK
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.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block.
(4) Check for continuity between each of the
blower motor switch input terminals of the resistor
and the resistor output terminal. In each case there
should be continuity. If OK, repair the wire harness
circuits between the blower motor switch and the
blower motor resistor, blower motor or blower motor
relay as required. If not OK, replace the faulty
blower motor resistor block.
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.
WARNING: THE BLOWER MOTOR RESISTOR
BLOCK MAY GET VERY HOT DURING NORMAL
OPERATION. IF THE BLOWER MOTOR WAS
TURNED ON PRIOR TO SERVICING THE BLOWER
MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES
TO ALLOW THE BLOWER MOTOR RESISTORS TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
24 - 26 CONTROLS - FRONTRS

Page 2422 of 2585

CHRYSLER VOYAGER 2004 Service Manual CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery n

CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block (Fig. 14).
(4) Remove the two screws that secure the blower
motor resistor block to the HVAC housing.
(5) Remove the resistor block from the HVAC
housing.
INSTALLATION
(1) Position the blower motor resistor block into
the HVAC housing.
(2) Install the two screws that secure the blower
motor resistor block to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the resistor
block.
(4) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
NOTE: The following applies to RS models only. RG
models use an expansion valve mounted evapora-
tor temperature sensor for both manual and auto-
matic temperature control systems due to A/C-
heater control calibration requirements.
The evaporator temperature sensor used for the
manual temperature control (MTC) system is
installed on the top of the HVAC housing behind the
instrument panel and measures the air temperature
downstream of the evaporator (Fig. 15). The sensor is
an electrical thermistor in a plastic housing that is
inserted into the HVAC housing. Two terminals
within the molded plastic connector receptacle on the
sensor connect it to the vehicle electrical system
through a take out and connector of the HVAC wire
harness.
The evaporator temperature sensor used for the
automatic temperature control (ATC) system is
installed on the top of the expansion valve in the
right rear corner of the engine compartment and
measures the temperature of the evaporator coils
(Fig. 16). The sensor has a small probe that is
Fig. 14 Blower Motor Resistor Block - Typical
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE HARNESS
6 - HVAC HOUSING
Fig. 15 Evaporator Temperature Sensor - MTC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - HVAC HOUSING
3 - A/C EVAPORATOR
RSCONTROLS - FRONT24-27
BLOWER MOTOR RESISTOR BLOCK (Continued)

Page 2423 of 2585

CHRYSLER VOYAGER 2004 Service Manual inserted in a small well in the body of the expansion
valve that is filled with a special silicone-based ther-
mal grease. A small molded plastic push-in retainer
secures the sensor to a threaded hole

inserted in a small well in the body of the expansion
valve that is filled with a special silicone-based ther-
mal grease. A small molded plastic push-in retainer
secures the sensor to a threaded hole in the top sur-
face of the expansion valve. Two terminals within a
molded plastic connector receptacle on the sensor
connect it to the vehicle electrical system through a
take out and connector of the HVAC wire harness.
The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the tem-
peratures it monitors. The A/C-heater control is con-
nected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator tem-
perature increases, the resistance of the sensor
decreases and the voltage monitored by the control
decreases. The control uses this monitored voltage
reading to an indication of the evaporator tempera-
ture. The A/C-heater control is programmed to
respond to this input by sending electronic messages
to the powertrain control module (PCM) over the pro-
grammable communications interface (PCI) data bus,
and the PCM then cycles the A/C compressor clutch
as necessary to optimize A/C system performance andto protect the system from evaporator freezing. The
external location of the sensor allows the sensor to be
removed or installed without disturbing the refriger-
ant in the system. The evaporator temperature sen-
sor is diagnosed using a DRBIIItscan tool. Refer to
Body Diagnostic Procedures.
REMOVAL
REMOVAL - AUTOMATIC TEMPERATURE
CONTROL (ATC)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the windshield wiper assembly from
the vehicle (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Remove the temperature sensor retainer from
the expansion valve (Fig. 17).
(5) Pull the evaporator temperature sensor away
from the expansion valve far enough to access the
red release ring on the wiring connector. Push the
red ring toward the connector to release the lock and
disconnect the wire harness connector from the tem-
perature sensor.
(6) Remove the evaporator temperature sensor
from the engine compartment.
Fig. 16 Evaporator Temperature Sensor - ATC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - A/C EXPANSION VALVE
Fig. 17 Evaporator Temperature Sensor - ATC
System
1 - RIGHT FRONT STRUT TOWER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - DASH PANEL
5 - RETAINER
24 - 28 CONTROLS - FRONTRS
EVAPORATOR TEMPERATURE SENSOR (Continued)

Page 2424 of 2585

CHRYSLER VOYAGER 2004 Service Manual REMOVAL - MANUAL TEMPERATURE
CONTROL (MTC)
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PAN

REMOVAL - MANUAL TEMPERATURE
CONTROL (MTC)
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the wire harness connector from the
evaporator temperature sensor located on the top of
the HVAC housing (Fig. 18).
(4) Remove the evaporator temperature sensor
from the HVAC housing.
INSTALLATION
INSTALLATION - AUTOMATIC TEMPERATURE
CONTROL (ATC)
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) Position the evaporator temperature sensor
into the right rear corner of the engine compartment.
(2) Reconnect the wire harness connector to the
evaporator temperature sensor.
(3) Position the evaporator temperature sensor
onto the top of the expansion valve with the sensor
probe inserted into the well in the expansion valve.(4) Install the temperature sensor retainer.
(5) Install the window wiper module (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(6) Reinstall the air cleaner housing into the right
side of the engine compartment.
(7) Reconnect the battery negative cable.
(8) Run the HVAC Cool Down test to verify system
is operating properly (Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).
INSTALLATION - MANUAL TEMPERATURE
CONTROL (MTC)
(1) Install the evaporator temperature sensor into
the top of the HVAC housing.
(2) Connect the wire harness connector to the
evaporator temperature sensor.
(3) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(4) Reconnect the negative battery cable.
INFRARED TEMPERATURE
SENSOR
DESCRIPTION
The infrared temperature sensor consists of two
infrared transducers that are concealed behind a
clear lens located near the bottom of the center panel
outlet near the top of the instrument panel center
bezel (Fig. 19). These sensors are used only on mod-
els equipped with the optional automatic tempera-
ture control (ATC) heating-A/C system. A molded
plastic connector receptacle on the bottom of the
panel outlet unit is concealed behind the center
bezel. A short, dedicated jumper wire harness routed
behind the center bezel connects the sensors directly
to the ATC A/C-heater control module near the bot-
tom of the center bezel. The infrared temperature
sensor is integral to the center bezel panel outlet
unit. The infrared sensors cannot be adjusted or
repaired and, if faulty or damaged, the center bezel
panel outlet unit must be replaced.
OPERATION
The dual infrared temperature sensors provide
independent measurement inputs to the Automatic
Temperature Control (ATC) heater-A/C control mod-
ule that indicates the surface temperature of the
driver seat and front seat passenger seat occupants.
By using a surface temperature measurement, rather
than an air temperature measurement, the ATC sys-
tem is able to adjust itself to the comfort level as per-
ceived by the occupant. This allows the system to
detect and compensate for other ambient conditions
Fig. 18 Evaporator Temperature Sensor - MTC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
3 - HVAC HOUSING
RSCONTROLS - FRONT24-29
EVAPORATOR TEMPERATURE SENSOR (Continued)

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