mileage CHRYSLER VOYAGER 1996 Service Manual

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION................... 1
JUMP STARTING, HOISTING AND TOWING.... 7MAINTENANCE SCHEDULES................ 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS........... 1
FLUID CAPACITIES....................... 2
INTERNATIONAL SYMBOLS................ 1INTRODUCTION......................... 1
PARTS AND LUBRICANT
RECOMMENDATIONS.................... 1
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopartbrand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organization should be used to service a Chrysler
Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
Fig. 1 International Symbols
NSLUBRICATION AND MAINTENANCE 0 - 1

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULE............... 2
MAINTENANCE SCHEDULEÐ
DIESEL ENGINE....................... 2SCHEDULEÐA (DIESEL).................. 2
SCHEDULEÐB (DIESEL).................. 3
UNSCHEDULED INSPECTION.............. 2
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Refer to the 1998 GS Service Manual for Gasoline
Engine and non-engine related Maintenance Sched-
ules.
MAINTENANCE SCHEDULEÐDIESEL ENGINE
The following are engine related Maintenance
items which are unique to Diesel engine-equipped
vehicles. Refer to the 1998 GS Service Manual for
Gasoline Engine and non-engine related Maintenance
Schedules.
The service intervals are based on odometer read-
ings in kilometers. There are two maintenance sched-
ules that show proper service intervals. Use the
schedule that best describes the conditions the vehi-
cle is operated under.Schedule-Alists all the sched-
uled maintenance to be performed under normal
operating conditions.Schedule-Bis the schedule for
vehicles that are operated under one or more of the
following conditions:
²Day and night temperatures are below freezing.
²Stop and go driving.
²Long periods of engine idling.
²Driving in dusty conditions.
²Short trips of less than 5 miles.
²Operation at sustained high speeds during hot
weather above 32ÉC (90ÉF).
²Taxi, police or delivery service.
²Trailer towing.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on ScheduleÐA (7,500 miles) or every other
interval shown on ScheduleÐ B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter.
SCHEDULEÐA (DIESEL)
1 000 KM
²Change engine oil.
²Change engine oil filter.
²Check all fluid levels.
²Check correct torque, intake manifold mounting
nuts.
²Check correct torque, exhaust manifold mount-
ing nuts.
²Check correct torque, turbocharger mounting
nuts.
²Check correct torque, water manifold bolts.
10 000 KM
²Change engine oil.
²Change engine oil filter.
20 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
0 - 2 LUBRICATION AND MAINTENANCENS/GS

The primary functions of the (CAB) are:
(1) Detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
(2) Illuminate the TRAC lamp in the message cen-
ter on the instrument panel when a traction control
event is occurring.
(3) Control fluid modulation to the wheel brakes
while the system is in an ABS mode or the traction
control system is activated.
(4) Monitor the system for proper operation.
(5) Provide communication to the DRB Scan Tool
while in diagnostic mode.
(6) Store diagnostic information.
(7)The CAB continuously communicates with
the body controller by sending out a message to
the body controller on the CCD Bus. This mes-
sage is used for illumination of the yellow
antilock warning lamp. This is used if the ABS
controller communication is lost in the hard
wire between the body controller and the yel-
low antilock warning lamp. If the body control-
ler does not receive this message from the CAB,
the body controller will illuminate the antilock
yellow warning lamp.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The CAB command coils then open and close the
valves in the HCU which modulate brake fluid pres-
sure in some or all of the hydraulic circuits. The CAB
continues to control pressure in individual hydraulic
circuits until a locking tendency is no longer present.
The ABS system is constantly monitored by the
CAB for proper operation. If the CAB detects a fault,
it will turn on the Amber ABS Warning Lamp anddisable the ABS braking system. The normal base
braking system will remain operational.
The CAB contains a self-diagnostic program which
will turn on the Amber ABS Warning Lamp when a
ABS system fault is detected. Faults are then stored
in a diagnostic program memory. There are multiple
fault messages which may be stored in the CAB and
displayed through the DRB Scan Tool. These fault
messages will remain in the CAB memory even after
the ignition has been turned off. The fault messages
can be read and or cleared from the CAB memory by
a technician using the DRB Scan Tool. The fault
occurrence and the fault code will also be automati-
cally cleared from the CAB memory after the identi-
cal fault has not been seen during the next 3500
miles of vehicle operation. Mileage though of the last
fault occurrence will not be automatically cleared.CONTROLLER ANTILOCK BRAKE INPUTS
²Four wheel speed sensors.
²Stop lamp switch.
²Ignition switch.
²System relay voltage.
²Ground.
²Traction Control Switch (If Equipped).
²Diagnostics Communications (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
²C2D Communication To Body Controller And
Instrument Cluster
²ABS warning lamp actuation.
²Traction Control Light (If Equipped).
²Diagnostic communication. (CCD)
ABS WARNING LAMP (YELLOW)
The ABS system uses a yellow colored ABS Warn-
ing Lamp. The ABS warning lamp is located on the
right side of the message center located at the top of
the instrument panel. The purpose of the warning
lamp is discussed in detail below.
The ABS warning lamp will turn on when the CAB
detects a condition which results in a shutdown of
ABS function or when the body controller does not
receive C2D messages from the CAB. When the igni-
tion key is turned to the on position, the ABS Warn-
ing Lamp is on until the CAB completes its self tests
and turns the lamp off (approximately 4 seconds
after the ignition switch is turned on). Under most
conditions, when the ABS warning lamp is on, only
the ABS function of the brake system is affected. The
standard brake system and the ability to stop the car
will not be affected when only the ABS warning lamp
is on.
The ABS warning lamp is controlled by the CAB
and the body controller through a diode located in
the wiring harness junction block. The junction block
is located under the instrument panel to the left of
Fig. 10 Controller Antilock Brake (CAB)
NSBRAKES 5 - 91
DESCRIPTION AND OPERATION (Continued)

START-UP CYCLE
The self diagnostic ABS start up cycle begins when
the ignition switch is turned to the on position. Elec-
trical checks are completed on ABS components, such
as the Controller, solenoid continuity, and the system
relay operation. During this check the Amber ABS
Warning Light is turned on for approximately 4 sec-
onds and the brake pedal may emit a popping sound
and move slightly when the solenoid valves are
checked.
DRIVE-OFF CYCLE
Further Functional testing is accomplished once
the vehicle is set in motion and reaches a speed of
about 20 kph (12 mph.). This cycle is performed only
once after each ignition on/off cycle.
²The pump/motor is activated briefly to verify
function. When the pump/motor is activated a whirl-
ing or buzzing sound may be heard by the driver,
which is normal when the pump/motor is running.
²The wheel speed sensor output is verified to be
within the correct operating range.
ONGOING TESTS
Other tests are performed on a continuous basis.
These include checks for solenoid continuity, wheel
speed sensor continuity and wheel speed sensor out-
put.
ABS DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC) are kept in the con-
troller's memory until either erased by the technician
using the DRB or erased automatically after 3500
miles. DTC's are retained by the controller even if
the ignition is turned off or the battery is discon-
nected. More than one DTC can be stored at a time.
The mileage of the most recent occurrence, number of
occurrences and the DTC that was stored is also dis-
played. Most functions of the CAB and the ABS sys-
tem can be accessed by the technician for testing and
diagnostic purposes by using the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTC's detected by the CAB are latching; the
DTC is latched and ABS braking is disabled until the
ignition switch is reset. Thus ABS braking is non
operational even if the original DTC has disappeared.
Other DTC's are non-latching; any warning lights
that are turned on, are only turned on as long as the
DTC condition exists. As soon as the condition goes
away, the ABS Warning Light is turned off, although
a DTC will be set in most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As with virtually any electronic system, intermit-
tent electrical problems in the ABS system may be
difficult to accurately diagnose.
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. When an
intermittent fault is encountered, check suspect cir-
cuits for:
A visual inspection for loose, disconnected, or mis-
routed wires should be done before attempting to
diagnose or service the ITT Teves Mark 20 antilock
brake system. A visual inspection will eliminate
unnecessary testing and diagnostics time. A thorough
visual inspection will include the following compo-
nents and areas of the vehicle.
(1) Inspect fuses in the power distribution center
(PDC) and the wiring junction block. Verify that all
fuses are fully inserted into the PDC and wring junc-
tion block. A label on the underside of the PDC cover
identifies the locations of the ABS fuses in the PDC.
(2) Inspect the 25-way electrical connector at the
CAB for damage, spread or backed-out wiring termi-
nals. Verify that the 25-way connector is fully
inserted in the socket on the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Poor mating of connector halves or terminals
not fully seated in the connector body.
(5) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(6) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
(7) Pin presence in the connector assembly
(8) Proper ground connections. Check all ground
connections for signs of corrosion, tight fasteners, or
other potential defects. Refer to wiring diagram man-
ual for ground locations.
(9) Problems with main power sources of the vehi-
cle. Inspect battery, generator, ignition circuits and
other related relays and fuses.
(10) If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the trouble code.
(11) Most failures of the ABS system will disable
ABS function for the entire ignition cycle even if the
fault clears before key-off. There are some failure
conditions, however, which will allow ABS operation
to resume during the ignition cycle in which a failure
occurred if the failure conditions are no longer
present. The following conditions may result in inter-
mittent illumination of the ABS Warning Lamp. All
other failures will cause the lamp to remain on until
the ignition switch is turned off. Circuits involving
NSBRAKES 5 - 97
DIAGNOSIS AND TESTING (Continued)

²available manifold vacuum
²barometric pressure
²engine coolant temperature
²engine RPM
²intake air temperature (2.4L only)
²throttle position
The PCM also regulates the fuel injection system.
Refer to the Fuel Injection sections of Group 14.
IGNITION SYSTEM
NOTE: The 2.4, 3.0 and 3.3/3.8L engines use a fixed
ignition timing system. Basic ignition timing is not
adjustable. All spark advance is determined by the
Powertrain Control Module (PCM).
The distributorless ignition system used on 2.4 and
3.3/3.8L engines is refered to as the Direct Ignition
System (DIS). The system's three main components
are the coil pack, crankshaft position sensor, and
camshaft position sensor. The crankshaft position
sensor and camshaft position sensor are hall effect
devices.
The 3.0L engine uses a distributor, crankshaft sen-
sor and ignition coil. The system's main components
are the distributor, distributor pickup, camshaft sig-
nal, crankshaft signal and ignition coil.
SPARK PLUGSÐ2.4/3.0L
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O - Lubrication and Maintenance.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Refer to the Spark Plug Condition section of
this group. After cleaning, file the center electrode
flat with a small flat point file or jewelers file. Adjust
the gap between the electrodes (Fig. 2) to the dimen-
sions specified in the chart at the end of this section.
Special care should be used when installing spark
plugs in the 2.4L cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to
the electrodes can occur.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N´m (20 ft. lbs.) torque.SPARK PLUGSÐ3.3/3.8L
The 3.3/3.8L engines utilize platinum spark plugs.
Refer to the maintenance schedule in Group 0 of this
service manual.
Fig. 1 Powertrain Control Module
Fig. 2 Setting Spark Plug Electrode Gap
8D - 2 IGNITION SYSTEMNS
GENERAL INFORMATION (Continued)

All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O - Lubrication and Maintenance.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Refer to the Spark Plug Condition section of
this group.
The spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal
driving conditions per schedule A in this manual. The
spark plugs have a recommended service life of
75,000 miles for serve driving conditions per schedule
B in this manual. A thin platinum pad is welded to
both electrode ends as show in (Fig. 3). Extreme care
must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during
plug removal and installation.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum plugs. This
would damage the platinum pads which would
shorten spark plug life.
Apply a very small amount of anti-seize compound
to the threads when reinstalling the vehicle's original
spark plugs that have been determined good.Do not
apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conduc-
tive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-
seize compound doesn't make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum
electrodes or adjust the gap on platinum spark plugs
without reading the 3.3/3.8L Spark Plug Gap Mea-
surement procedures in this section.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N´m (20 ft. lbs.) torque.
Due to the engine packaging environment for the
3.3/3.8L engines, extreme care should be used wheninstalling the spark plugs to avoid cross threading
problems.
3.3/3.8L SPARK PLUG GAP MEASUREMENT
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
²USE ONLY A TAPER GAP GAUGE (Fig. 2)
²Never force the gap gauge through the platinum
pads. Only apply enough force until resistance is felt.
²Never use a wire brush or spark plug cleaner
machine to clean platinum spark plugs
²Use an OSHA approved air nozzle when drying
gas fouled spark plugs.
If gap adjustment is required of platinum plug,
bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool
and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.
SPARK PLUG CABLE
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack, distributor
(3.0L), to individual spark plugs at each cylinder. The
resistive spark plug cables are of nonmetallic con-
struction. The cables provide suppression of radio fre-
quency emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil, distributor cap towers (3.0L), and
spark plugs. Terminals should be fully seated. The
insulators should be in good condition and should fit
tightly on the coil, distributor (3.0L) and spark plugs.
Spark plug cables with insulators that are cracked or
torn must be replaced.
Fig. 3 Platinum Pads
NSIGNITION SYSTEM 8D - 3
GENERAL INFORMATION (Continued)

API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 Engine Oil Container Standard Notations
9 - 6 ENGINENS
GENERAL INFORMATION (Continued)

HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 3.5 bars to 5.0 bars at 4000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these 2 condi-
tions could be responsible for noisy tappets.
OIL LEVEL HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
OIL LEVEL LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre-
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a suf-
ficient time to allow all of the air inside the tappets
to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak down around the unit plunger or by the
plunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click iscaused by a tappet check valve not seating or by for-
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, tappet assembly should be removed for inspec-
tion and cleaning.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
ing the noise. In general, if more than one tappet
seems to be noisy, its probably not the tappets.
SERVICE PROCEDURES
CHECKING OIL LEVEL
To assure proper engine lubrication, the engine oil
must be maintained at the correct level. Check the
oil level at regular intervals, such as every fuel stop.
The best time to check the oil level is about 5 min-
utes after a fully warmed-up engine is shut off, or
before starting the vehicle after it has sat overnight.
Checking the oil while the vehicle is on level
ground, will improve the accuracy of the oil level
readings (Fig. 4).
CHANGING ENGINE OIL AND FILTER
Change engine oil and filter at mileage and time
intervals described in the Maintenance Schedule.
Fig. 4 Checking Engine Oil
NS/GSENGINE 9 - 47
DIAGNOSIS AND TESTING (Continued)

FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM................... 4
FUEL INJECTION SYSTEM................. 29GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CRUISING RANGE........................ 3
E-85 GENERAL INFORMATION.............. 2
ETHANOL FUEL (E-85).................... 2
FUEL REQUIREMENTS.................... 1
FUEL REQUIREMENTS.................... 2GASOLINE/OXYGENATE BLENDS............ 2
INTRODUCTION......................... 1
PCM REPLACEMENT..................... 1
REPLACEMENT PARTS.................... 3
STARTING.............................. 2
GENERAL INFORMATION
INTRODUCTION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
The Evaporation Control System, is also considered
part of the fuel system. The system reduces the emis-
sion of fuel vapor into the atmosphere.
The description and function of the Evaporation
Control System is found in Group 25 of this manual.
PCM REPLACEMENT
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
FUEL REQUIREMENTS
Your vehicle was designed to meet all emission reg-
ulations and provide excellent fuel economy when
using high quality unleaded gasoline.
Use unleaded gasolines having a minimum posted
octane of 87.
If your vehicle develops occasional light spark
knock (ping) at low engine speeds this is not harm-
ful. However; continued heavy knock at high speeds
can cause damage and should be reported to your
dealer immediately. Engine damage as a result of
heavy knock operation may not be covered by the
new vehicle warranty.
In addition to using unleaded gasoline with the
proper octane rating, those that contain detergents,
corrosion and stability additives are recommended.
Using gasolines that have these additives will help
improve fuel economy, reduce emissions, and main-
tain vehicle performance.
Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.
NSFUEL SYSTEM 14 - 1