torque CHRYSLER VOYAGER 1996 Service Manual

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
REMOVAL
(1) Disconnect electrical connector from MAP sen-
sor.
(2) Remove 2 screws holding sensor to intake man-
ifold (Fig. 9).
(3) Remove sensor from manifold.
INSTALLATION
Reverse the above procedure for installation.
ENGINE COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature (ECT) sensor is
located below the ignition coil (Fig. 10).
REMOVAL
(1) Drain cooling system until coolant level is
below sensor. Refer to Group 7, Cooling System.
(2) Remove electrical connector from coil (Fig. 11).
(3) Remove coil mounting screws.
(4) Rotate coil away from engine coolant tempera-
ture sensor.
(5) Disconnect electrical connector from engine
coolant temperature sensor.
(6) Remove sensor from engine.
INSTALLATION
(1) Tighten the sensor to 7 N´m (60 in. lbs.) torque.
(2) Connect electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
(4) Install coil. Tighten coil mounting screws to 12
N´m (105 in. lbs.) torque.
(5) Connect electrical connector to coil.
THROTTLE POSITION SENSOR
Refer to Group 14, Fuel Injection Section, for
Removal/Installation.
KNOCK SENSORÐ3.3/3.8L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
Fig. 8 Camshaft Position Sensor and Spacer
Fig. 9 Manifold Absolute Pressure Sensor
Fig. 10 Engine Coolant Temperature Sensor
Fig. 11 Ignition Coil Removal
8D - 32 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
SPECIFICATIONS
IGNITION COILFig. 12 Knock Sensor
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-
27ÉC (70ÉF-80ÉF)
Weastec (Aluminum Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Diamond Electric (Brass Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Coil PolarityCoil Polarity
NSIGNITION SYSTEM 8D - 33
REMOVAL AND INSTALLATION (Continued)

SPARK PLUG
* New Spark Plug Gap
TORQUE
DESCRIPTION......................TORQUE
3.3L Camshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3L Engine Coolant Sensor......7N´m(60in.lbs.)
3.3L Crankshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3/3.8L Ignition Coil.........12N´m(105 in. lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(20ft.lbs.)
SPARK PLUG CABLE RESISTANCEÐ3.3/3.8L
Engine Spark Plug Gap * Thread Size
3.3L RN14PMP5 0.048 TO 0.053 14mm (3/4 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (3/4 in. ) reach
CABLE Maximum
Resistance
#1 18.5K ohms
#2 15.5K ohms
#3 20.4K ohms
#4 21.2K ohms
#5 27.7K ohms
#6 26.7K ohms
8D - 34 IGNITION SYSTEMNS
SPECIFICATIONS (Continued)

(2) Remove forward lower console from instrument
panel, refer to Group 8E, Instrument Panel and Sys-
tems for proper procedures.
(3) Remove screw holding lower heat duct to
instrument panel support (Fig. 3).
(4) Remove heat duct from instrument panel.
(5) Remove two bolts holding top of right support
to instrument panel (Fig. 4).
(6) Remove two bolts holding bottom of right sup-
port to floor pan.
(7) Separate right instrument panel support from
vehicle.
(8) Disconnect two wire connectors from ACM (Fig.
5).
(9) Remove four bolts holding the ACM bracket
assembly to floor (Fig. 6).
(10) Remove the ACM from vehicle.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLD-
ING THE ACM TO THE ACM BRACKET. THESE
BOLTS ARE SAFETY TORQUED AT THE MANUFAC-
TURING FACILITY AND SHOULD NOT BE REMOVED
FOR ANY REASON. THE NEW ACM WILL COME
WITH A NEW BRACKET INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN
INSTALLING THE ACM
For installation, reverse the above procedures.
Attach the ACM bracket assembly to vehicle with the
proper screws and tighten to 805 to 11.9 N´m (75 to
105 in. lbs.) torque. Do not connect battery negative
cable. Refer to Diagnosis and Testing for Airbag Sys-
tem Test procedures.
Fig. 3 Heat Duct
Fig. 4 Instrument Panel Supports
Fig. 5 ACM Connectors
Fig. 6 ACM Bracket Assembly
8M - 4 RESTRAINT SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

If motor grunts and does not move, verify that reg-
ulator is not binding.
WIRING VOLTAGE TEST
The following wiring test determines whether or
not voltage is continuous through the body harness
to switch.
(1) Remove the master power window switch and
bezel assembly from the driver door. Refer to Group
23, Body for proper procedures.
(2) Disconnect wire connector from back of power
window switch.
(3) Switch ignition ON position.
(4) Connect the clip end of a 12 volt test light to
Pin 13 in door harness connector at the window
switch. Touch the test light probe to Pin 9 and then
to Pin 11.
²If the test light illuminates, the wiring circuit
between the battery and switch is OK.
²If light does not illuminate, check the 40 amp
fuse in the Power Distribution Center or for a broken
wire.
²The power window motors are protected with
Positive Temperature Coefficient (PTC) device that
prevents motor burn out. Check Junction Block.
²Refer to Group 8W, Wiring Diagrams for circuit
information and component locations.
REMOVAL AND INSTALLATION
POWER VENT WINDOW MOTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove D-pillar trim panel.
(3) Disconnect wire connector from power vent
motor.
(4) Remove nut holding crank to vent glass.
(5) Remove bolts holding power vent motor to
D-pillar (Fig. 4).
(6) Remove power vent motor.
(7) Pull the crank system from the motor.
INSTALLATION
Before installing crank, cycle replacement motor to
the open position. Install crank hinge in extended
position to the motor and for installation, reverse the
above procedures.
POWER WINDOW SWITCH
To remove power window switches refer to Group
23, Body for proper procedures.
POWER WINDOW MOTOR
WARNING: DO NOT HAVE ANY HANDS OR FIN-
GERS IN SECTOR GEAR AREA WHERE THEY CAN
BE PINCHED BY SMALL MOVEMENTS OF REGULA-
TOR LINKAGE.
REMOVAL
(1) Tape the window in its existing position to
remove its weight from the regulator system.
(2) Cut and remove the tie wrap at the window
motor. Its no longer required.
(3) Disconnect window motor wire connector from
door harness.
(4) Remove screws and nuts holding window motor
to the inner panel.
(5) Remove the motor from the door inner panel,
let it hang from the cables.
(6) With the cables still attached to the failed
motor, Install the replacement motor to the door
inner panel. Tighten down the screws and nuts to 3.4
to 4.5 N´m ( 30 to 40 in. lbs.) of torque.
(7) Separate the failed motor from regulator by:
²Removing the drum cover plate.
²Lift the cable guide off the motor, the drum with
cables, will be lifted off simultaneously (Fig. 5).
CAUTION: Do not allow the drum to separate from
the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION
(1) Install the cable guide and drum into the
replacement motor.
Fig. 4 Vent Window Motor
NSPOWER WINDOWS 8S - 3
DIAGNOSIS AND TESTING (Continued)

POWERTRAIN
CONTROL
MODULE C1
35
K22
18
OR/DB
OR/DB18 K22
ES08MODULE CONTROL
TRANSMISSION
12
SIGNAL SENSOR POSITION THROTTLE THROTTLE
POSITION
SENSOR
SIGNAL SIGNAL SENSOR POSITION CRANKSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
6
ES05
K24
18
GY/BK GY/BK18 K24
32C1
BK/YL18 T41
76C2
10
P/N
TRANSMISSION
RANGE
SENSOR
SERVO CONTROL
SPEED
VEHICLE
13
4
STOP
LAMP
SWITCH
V30
18
DB/RD
213
C280
VENT
SOLENOID SOLENOIDVACUUM
56C2
V35
18
LG/RD
TN/RD18 V36
3E43
B707
E43 B706 YL/RD18 V32
5C1C262
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL SOLENOIDVENT CONTROLSPEED
WT/PK20 K29 V32
20
YL/RD STOP LAMP
SWITCH
SENSESPEED
CONTROL
ON/OFF
SWITCH SENSE
2
6
G300
BK20Z1
DB/RD20 V30
GENERATOR
FIELD DRIVER
K20
18
DG
8C1
2
GENERATOR
TRANSMISSION
RANGE
SWITCH
T41
SENSE
10
YL/DG18 T10
SENSE REQUEST MANAGEMENTTORQUE
TORQUE
MANAGEMENT
REQUIREMENT
SENSE 63
C2
7
ST-RUN V23
CENTER MESSAGESERVICE
ENGINE
SOON
LAMP
C122
INDICATOR SERVICE ENGINE SOON5
B70
E43
P34
B232
A2G3
20
BK/PK
BK/PK20 G3
BK/PK18 G3 *13
* RHD
RHD LHD
JUNCTION
BLOCK
TOGENERATOR
FIELD
DRIVER
LAMP DRIVER (8W-70-8) (8W-70-8)
(8W-31-5)
(8W-33-3) (8W-33-3)
(8W-15-7)(8W-20-2) (8W-31-4)
(8W-31-8)(8W-12-9)
(8W-46-3)
(8W-12-19)
NS/GS8W-30 FUEL/IGNITION SYSTEM
2.4L8W - 30 - 19
GS003019J988W-3

POWERTRAIN
CONTROL
MODULE
BR/YL18 T41
76C2
TRANS
RANGE
SWITCH
T41
SENSE
P/N
10
SERVO CONTROL
SPEED
VEHICLE
13
4
STOP
LAMP
SWITCH
V30
18
DB/RD
213
C280
VENT
SOLENOID SOLENOIDVACUUM
56C2
V35
18
LG/RD
TN/RD18 V36
3E43
B707
E43 B706 YL/RD18 V32
5C1C262
K29
18
WT/PK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL CONTROL SOLENOIDVENT CONTROLSPEED
WT/PK20 K29 V32
20
YL/RD STOP
LAMP
SWITCH
SENSESPEED
CONTROL
ON/OFF
SWITCH
SENSE
2
6
G300
BK20Z1DB/RD20 V30
TRANSMISSION
RANGE
SENSOR
2
8C1
K20
18
DG
DRIVERFIELD GENERATOR
GENERATOR
7
ST-RUN V23
CENTER
MESSAGESERVICE
ENGINE
SOON
LAMP
C122
INDICATOR LAMP DRIVERSERVICE ENGINE SOON5
B70
E43
P34
B232
A2G3
20
BK/PK
BK/PK20 G3
BK/PK18 G3 *13
RHD LHD
JUNCTION
BLOCK
TO
* RHD GENERATOR
FIELD
DRIVER
10
TRANSMISSION
CONTROL
MODULE
C2
63
T10
18
YL/DG
TORQUE
MANAGEMENT
REQUIREMENT
SENSE SENSE REQUIREMENTMANAGEMENTTORQUE
(8W-33-3) (8W-33-3)
(8W-15-7)(8W-31-5) (8W-20-2) (8W-12-9)
(8W-46-3)
(8W-12-19)(8W-31-8)
NS/GS8W-30 FUEL/IGNITION SYSTEM
3.3L/3.8L8W - 30 - 27
GS003027J988W-3

MODULE CONTROL
TRANSMISSION
CCD
BUS
(-) WT/BK18 D2
4
CCD
BUS
(+) VT/BR18D1
43
SCI
TRANSMIT
MODULE CONTROL
POWERTRAIN
65C2 C263
T10
18
YL/DG
10
SCI
RECEIVE
46PK/LB18 D6
TORQUE
MANAGEMENT
REQUIREMENT
SENSE
SCI
TRANSMIT
7PK18 D21
TORQUE
MANAGEMENT
REQUEST
SENSE
D6
20
PK/LB
D21
18
PK
7
14
DATA
LINK
CONNECTOR
ES24
PK18 D21
D1
20
VT/BR D2
20
WT/BK
311
PS01 PS02
P18
B23
E36 B33
6
D6
20
PK/LB
P18
B23 E36
B334
WT/BK20 D2
VT/BR20 D1
72
ES14 ES13
BS06 BS05
D21
20
PK
B17
17
13
B1312
B1214
B14
D1
18
VT/BR D2
18
WT/BK
PAIR TWISTED
PAIR TWISTED
(8W-30-3)
(8W-30-19)
(8W-30-27)
(8W-30-3)
(8W-30-4) (8W-30-3)
(8W-30-4) (8W-30-4)
(8W-30-4) (8W-30-4) (8W-30-4) (8W-30-4)
8W - 31 - 8 8W-31 TRANSMISSION CONTROL SYSTEMNS/GS
J988W-3GS003108

MODULE - C2CONTROL POWERTRAIN
K70 18VT/RD PULSE WIDTH MODULATED PURGE CURRENT SENSE- -
80 7161 51 41
70 60 50GRAY
V35 18LG/RD K106 18WT/DG T41 18BR/YL D20 18LG K31 18BR
K173 14LG/DB K107 18YL/BK K52 18PK/BK K51 18DB/YL G7 18WT/OR D21 18PK C13 18DB/OR T10 18YL/DG K29 18WT/PK
K6 18VT/WT D2 18WT/BK D1 18VT/BR
K59 18VT/BK K39 18GY/RD V36 18TN/RD K141 18TN/WT Z12 18BK/TN
K60 18YL/BK K40 18BR/WT A14 18RD/WT K7 18OR K4 18BK/LB C18 18DB V37 18RD/LG
80 79 78
77 76 75
74 73 72
71 70 69
68 67 66 65 64 63
62 61 60
59 58 57
56 55 54
53 52 51
50 49 48
47 46 45
44 43 42
41 CAV SPEED CONTROL VENT SOLENOID CONTROL EVAP LEAK DETECTION PUMP SOLENOID CONTROL TRANSMISSION RANGE SWITCH T41 SENSE SCI RECEIVE FUEL PUMP RELAY CONTROL
RADIATOR FAN RELAY CONTROL EVAP LEAK DETECTION PUMP STROKE SENSE EVAP/PURGE SOLENOID CONTROL AUTOMATIC SHUT DOWN RELAY CONTROL VEHICLE SPEED SENSOR SIGNAL SCI TRANSMIT A/C COMPRESSOR CLUTCH RELAY CONTROL TORQUE MANAGEMENT REQUEST SENSE STOP LAMP SWITCH SENSE
5 VOLT SUPPLY CCD BUS (-) CCD BUS (+)
IDLE AIR CONTROL MOTOR NO. 4 DRIVER IDLE AIR CONTROL MOTOR NO. 1 DRIVER SPEED CONTROL VACUUM SOLENOID CONTROL HEATED OXYGEN SENSOR SIGNAL GROUND
IDLE AIR CONTROL MOTOR NO. 2 DRIVER IDLE AIR CONTROL MOTOR NO. 3 DRIVER FUSED B(+) 8 VOLT SUPPLY SENSOR GROUND A/C PRESSURE SWITCH SIGNAL SPEED CONTROL SWITCH SIGNAL
- - - - - - - CIRCUIT
- - - - - - - FUNCTION
EATX
- -
* 3.3L/3.8L ENGINE K50 18YL/WT* FLEXIBLE FUEL SENSOR SIGNAL
FUNCTION
CIRCUIT
FUSED B(+)
IGNITION SWITCH OUTPUT (OFF/RUN/START)CAV
1
2M1 20PK
A81 20DG/RD
BLACK
21
PRNDL FEED
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8072

MODULE CONTROL TRANSMISSION
(CONTINUED ON NEXT PAGE)
BLACK
+ + + + + + + + +
2011 101
6051 50
40 21
41
T20 18LB T19 18WT T16 18RD T16 18RD
T15 18LG T14 18LG/WT
T13 18DB/BK K22 18OR/DB F11 18RD/WT
T10 18YL/DG T9 18OR/BK F45 18YL/RD
D21 18PK K24 18GY/BK D2 18WT/BK T3 18VT T1 18LG/BK
40 39
38 37 36
35 34 33
32 31 30
29 28 27
26 25 24
23 22 21
20 19 18
17 16 15
14 13 12
11 10 9
8 7 6
5 4 3
2 1 CAV LOW/REVERSE SOLENOID CONTROL
2-4 SOLENOID CONTROL TRANSMISSION CONTROL RELAY OUTPUT TRANSMISSION CONTROL RELAY OUTPUT
12 VOLT SUPPLY OUTPUT SHAFT SPEED SENSOR SIGNAL
SPEED SENSOR GROUND THROTTLE POSITION SENSOR SIGNAL FUSED IGNITION (ST-RUN-OFF)
TORQUE MANAGEMENT REQUEST SENSE OVERDRIVE PRESSURE SWITCH SENSE FUSED IGNITION (ST)
SCI TRANSMIT CRANKSHAFT POSITION SENSOR SIGNAL CCD BUS(-) TRANSMISSION RANGE SWITCH T3 SENSE TRANSMISSION RANGE SWITCH T1 SENSE
- -
- - -
- - -
- - -
- - -
- - -
- - - - - - CIRCUIT
- -
- - -
- - -
- - -
- - -
- - -
- - - - - - FUNCTION
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85
NSGS8085J988W-3