1996 Plymouth Voyager lACK OF HEAT

Tiny
DICK BURKE
  • MEMBER
  • 1996 PLYMOUTH VOYAGER
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 125,800 MILES
Recently the heater stopped heating, pushing the slide bar to heat did not result in heat. Taking off the pannel showed an electrical connector with about twenty pins, no push-pull cable. Feeling the two hoses on the front side of the fire wall are both HOT seems to indicate that there is flow through the core and that it is not plugged. Question, how do I fix the electricaly controled dampers to provide heat?

updated 12/1/09
Hello 2CarPros; I am not making much progress with my Lack of Heat; I recieved a reply from Merlin 2021 on Nov 23 which gave a longish diagnostic proceedure which seemed too complicated for me to do and anyway if it showed the trouble I probably couldn't fix it so I took it to a Dealer who had some past connection to Chrysler. They said they went through some such proceedure and found that both the right and lefthand flappers didn't work which they thought odd as usually both don't go bad at once. They said that to go further they would have to take off the dashboard and that would cost about $700.00 so I told them to stop. They charged me $102.00.
So what I need now is information on where to cut away the plastic so that I can get access to the damppers to clean out the mouse nest, oil the hinges, disconnect the potentiometers to see if they work, and if necessary attach push-pull choke cables so that at least I can work them by hand.
Your help would be much appreciated because this is not just a matter of comfort, but as winter comes on I will need the defogger and deicer systems to work, and for this I need the heat to work. Many thanks,

updated 12/12/09
The car now has heat in a jury-rigged sort of way;
Results of diagnostic tests Wash flash once, Int flash 5;Wash flash twice, Int flash Blinking, rate increases/decreases as move from Pannel to defrost, {so OK]; Wash flash thrice, {blend & Heat test], Int flash Blinking, No change in rate as temp slide bar moved from hot to cold [So BAD] Wash flash 4 times; Int flash 4, then going to 8 or 9, or a sequence of 4 followed by 5 going to 4 or 3; Wash flash five times, Int flashes once. After the above word "BAD" I dont know what all the flashes mean as I don't have a code book.

While doing all this I noticed that when the testing sequence was first started up after about ten seconds all the lights on the pannel would flash for about another ten seconds and then stop as the testing sequence was ready. During the ten seconds of all flashing the tone of the assembly would get more intense-louder- and there would be heat. When the lights stoped flashing the tone and the heat went away and never came back during the rest of the testing. I could repeat this event by restarting the whole procedure and I would get heat again no matter wheather the slide bar was on HOT or COLD.

Some one sugested that I unplug the [Passenger Zone?] Actuator in the middle of the time when it was making heat so I did this by turning off the ignition in the middle of the heat time frame, pulling the plug, and restarting the car, and it worked. Now I have heat constantly and it feels gooood, so I am OK untill Easter. One odd thing is that the wiper and intrmdiat lights now keep flashing and I can't make them go off, no big deal I supose. The unit cycles through all the positions from Pannel to Defrost OK.

I am wondering is there now enough information to say that some control module should be replaced to restor normalacy, what does it look like, where is it located, what number, what $$. OR could/can the whole thing have be corrected by "reflashing the computer" and have saved all this cotton picking work? It seems I should ask these questions before I reinstall/rebuild the dashboard.

Thanks for sticking with me through all this, take another $20.00 contribution and thanks again.
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Sunday, November 22nd, 2009 AT 11:16 AM

3 Replies

Tiny
MERLIN2021
  • EXPERT
IN-VEHICLE CALIBRATION 1. Mode and blend door calibration compensates for mechanical differences in actuators, heater unit and its linkages. In-vehicle calibration is entered using switches and buttons on Heat Vent Air Conditioner (HVAC) front panel. If rear wiper and intermittent LEDs flash simultaneously when ignition is turned on, actuators have not been calibrated or a previous calibration failure occurred. Diagnostics will always occur during calibration. 2. To enter calibration/diagnostics test, set parking brake. Start and warm engine to normal operating temperature. With engine idling, turn blower switch to high. Turn mode switch to panel (air comes from instrument panel outlets). Move temperature lever to full cold. Press and hold rear wash and wiper buttons for 5 seconds (until all LEDs illuminate). Rear wiper and intermittent button LEDs will flash alternately during calibration test. 3. After approximately 60 seconds, if only wiper button LED is flashing, calibration is successful and system is okay. If wiper and intermittent LEDs are flashing, see DIAGNOSTICS under TROUBLESHOOTING for diagnostic procedures. 4. To exit calibration/diagnostics test at any time, press rear wiper button or cycle ignition off and then on. Test will automatically terminate 15 minutes after calibration/diagnostics is entered. TROUBLE SHOOTING DIAGNOSTICS 1. If wiper and intermittent LEDs are flashing simultaneously, perform calibration test. See IN- VEHICLE CALIBRATION under ADJUSTMENTS. If wiper and intermittent LEDs are flashing alternately, level one codes are present. Wiper LED indicates display level. Each time wash button is pressed, display will cycle to next level. 2. One flash indicates fail codes. A 2-flash sequence indicates mode potentiometer test. A 3-flash sequence indicates blend potentiometer test. Intermittent LED indicates failure code (level 1) or potentiometer position (level 2 or 3). See FAILURE CODE VALUES table. 3. Temperature and mode potentiometers can be tested after calibration is complete by pressing wash button and cycling to level 2 or 3 as displayed by wiper LED. Press wash button once, wiper LED will begin a 2-flash sequence. Move mode selector switch from panel to defrost. Intermittent LED flash rate should decrease. Move mode selector switch from defrost to panel. Intermittent LED flash rate should increase. 4. Press wash button again, wiper LED will begin a 3-flash sequence. Move temperature selector lever from cold to hot. Intermittent LED flash rate should increase. Move temperature selector lever from hot to cold. Intermittent LED flash rate should decrease. NOTE: Whenever heater control panel, heater unit, doors or door actuators are replaced, actuator calibration/diagnostics test must be performed. WARNING: To avoid injury from accidental air bag deployment, read and follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.


http://www.2carpros.com/forum/automotive_pictures/62217_calibration_1.jpg


MAIN BLEND-AIR DOOR ACTUATOR Removal & Installation Remove left side lower column cover. Remove ABS control module. Remove blend-air door actuator connector. Remove blend-air door actuator. To install, reverse removal procedure. Perform calibration and test procedure. See IN-VEHICLE CALIBRATION under ADJUSTMENTS. MAIN MODE DOOR ACTUATOR Removal & Installation Remove left side lower column cover. Remove ABS control module. Remove mode door actuator connector. Remove mode door actuator. To install, reverse removal procedure. Perform calibration and test procedure. See IN-VEHICLE CALIBRATION under ADJUSTMENTS.
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Monday, November 23rd, 2009 AT 7:20 AM
Tiny
MERLIN2021
  • EXPERT
At the steering wheel:MAIN BLEND-AIR DOOR ACTUATOR Removal & Installation Remove left side lower column cover. Remove ABS control module. Remove blend-air door actuator connector. Remove blend-air door actuator. To install, reverse removal procedure. Perform calibration and test procedure. See IN-VEHICLE CALIBRATION under ADJUSTMENTS. MAIN MODE DOOR ACTUATOR Removal & Installation Remove left side lower column cover. Remove ABS control module. Remove mode door actuator connector. Remove mode door actuator. To install, reverse removal procedure. Perform calibration and test procedure. See IN-VEHICLE CALIBRATION under ADJUSTMENTS.
After you replace an actuator you MUST perform the calibration desribed above, or it will not work!
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Thursday, December 3rd, 2009 AT 2:05 PM
Tiny
MERLIN2021
  • EXPERT
1. Mode and blend door calibration compensates for mechanical differences in actuators, heater unit and its linkages. In-vehicle calibration is entered using switches and buttons on Heat Vent Air Conditioner (HVAC) front panel. If rear wiper and intermittent LEDs flash simultaneously when ignition is turned on, actuators have not been calibrated or a previous calibration failure occurred. Diagnostics will always occur during calibration. 2. To enter calibration/diagnostics test, set parking brake. Start and warm engine to normal operating temperature. With engine idling, turn blower switch to high. Turn mode switch to panel (air comes from instrument panel outlets). Move temperature lever to full cold. Press and hold rear wash and wiper buttons for 5 seconds (until all LEDs illuminate). Rear wiper and intermittent button LEDs will flash alternately during calibration test. 3. After approximately 60 seconds, if only wiper button LED is flashing, calibration is successful and system is okay. If wiper and intermittent LEDs are flashing, see DIAGNOSTICS under TROUBLESHOOTING for diagnostic procedures. 4. To exit calibration/diagnostics test at any time, press rear wiper button or cycle ignition off and then on. Test will automatically terminate 15 minutes after calibration/diagnostics is entered. NOTE: Whenever heater control panel, heater unit, doors or door actuators are replaced, actuator calibration/diagnostics test must be performed.
I sent a full PDF to your email, Read part 3 of this post. If I have it right, you got 4 flashes? This indicates the blend door didnt reach the full heat stop, possibly requiring a new actuator.
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Tuesday, December 15th, 2009 AT 3:02 PM

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