warning CHRYSLER VOYAGER 1996 Service Manual

X3 20BK/RD
HORN RELAY CONTROL L110 22BK/YL
AUTO HEADLAMP SWITCH SENSE
BA
BLACK
40 30 20 10
31 21 11 NATURAL
1
Z1 20BK G9 20GY/BK
B A CAV GROUND RED BRAKE WARNING LAMP DRIVER CIRCUIT
FUNCTION
L308 20LG/WT V26 22YL/WT D9 22GY/BK D2 20WT/BK G6 22GY G19 20LG/OR G69 22BK/OR Z2 20BK/LG L307 20LG/OR E17 20YL/BK Z2 20BK/LG Z20 20BK/WT** E92 22OR/BK
V52 20DG/YL G2 22VT G26 20LB D1 20VT/BR M32 22BK/LB
G96 20LG/RD
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 PARK LAMP SWITCH SENSE REAR WIPER SWITCH MUX RKE MODULE PROGRAM ENABLE CCD BUS(-) ENGINE OIL PRESSURE SWITCH SENSE ABS WARNING LAMP DRIVER VTSS LAMP DRIVER GROUND HEADLAMP SWITCH SENSE STEP DIMMER SWITCH SENSE GROUND GROUND DIMMER SWITCH SIGNAL
FRONT WIPER SWITCH MUX ENGINE TEMPERATURE WARNING LAMP DRIVER KEY-IN IGNITION SWITCH SENSE CCD BUS(+) COURTESY LAMP SWITCH SENSE RKE INTERFACE
- - - -
- - -
- - - - - -
- - - - - CIRCUIT
- - - -
- - -
- - - - - -
- - - - - FUNCTION
P136 20YL
POWER FOLDING MIRROR SWITCH SIGNAL
* BUILT-UP-EXPORT
** EXCEPT BUILT-UP-EXPORT
GAS
BODY
CONTROL
MODULE - C2
BRAKE PRESSURE
SWITCH
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8016

31 BLACK
9 8 7 1
25 24
23
1617 10NATURAL
K24 18GY/BK K4 18BK/LB
K7 18OR
3 2 1 CAV CRANKSHAFT POSITION SENSOR SIGNAL
SENSOR GROUND
8 VOLT SUPPLY CIRCUIT
FUNCTION
A10 12RD/DG Z7 12BK
F20 18WT B27 18RD/YL D1 18VT/BR D2 18WT/BK B6 18WT/DB
B2 18YL G19 18LG/OR L50 18WT/TN B8 18RD/DB B4 18LG A20 12RD/DB
Z7 12BK B9 18RD B7 18WT
B3 18LG/DB B1 18YL/DB
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 FUSED B(+)
GROUND FUSED IGNITION (RUN) TRACTION CONTROL SWITCH SENSE CCD BUS (+) CCD BUS (-) RIGHT FRONT WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (+) ABS WARNING LAMP DRIVER STOP LAMP SWITCH SENSE LEFT FRONT WHEEL SPEED SENSOR (-) LEFT REAR WHEEL SPEED SENSOR (+) FUSED B(+)
GROUND LEFT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL SPEED SENSOR (+)
LEFT REAR WHEEL SPEED SENSOR (-) RIGHT REAR WHEEL SPEED SENSOR (-)
- - - - - - - FUNCTION
- - - - - - - CIRCUIT
1 2
CRANK CASE
HEATER
(DIESEL)
GROUND Z1 18BK
2
1A141 18DG/WT CAV FUNCTION CIRCUIT
FUEL PUMP RELAY OUTPUT
BRAKE ANTI-LOCK CONTROLLER
SENSOR POSITION CRANKSHAFT
BLACK*
* DIESEL
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19
NSGS8019J988W-3

IGNITION SWITCH - C1
BLACK
106 51
A41 12YL A21 12DB A31 12BK/WT A1 12RD A22 12BK/OR A2 12PK/BK G9 20GY/BK Z1 20BK
109 8
7 6 5
4 3 2
1 CAV IGNITION SWITCH OUTPUT (START) IGNITION SWITCH OUTPUT (ST-RUN) IGNITION SWITCH OUTPUT (RUN-ACC) FUSED B(+) IGNITION SWITCH OUTPUT (RUN) FUSED B(+) RED BRAKE WARNING LAMP DRIVER GROUND
- - CIRCUIT
- - FUNCTION
IGNITION SWITCH - C2
2 1GREEN
Z1 20BK G26 20LB
2 1 CAV GROUND
KEY-IN IGNITION SWITCH SENSE CIRCUIT
FUNCTION
IGNITION SWITCH - C3
1 2BLACK
A81 20DG/RD M1 20PK
2 1 CAV IGNITION SWITCH OUTPUT (OFF/RUN/START) FUSED B(+) CIRCUIT
FUNCTION
INSTRUMENT CLUSTER
RED
7 1
136
11
Z1 20BK F11 20RD/WT D1 20VT/BR D2 20WT/BK Z2 20BK/LG E2 20OR M1 20PK
13 12 10 9 8 7 6
5 4
3 2 1 CAV GROUND FUSED IGNITION (ST-RUN-OFF) CCD BUS (+) CCD BUS (-) GROUND PANEL LAMPS FEED FUSED B(+)
- - - -
- - CIRCUIT
- - - -
- - FUNCTION
8W - 80 - 42 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8042

BUILT-UP-EXPORT
RIGHT TURN SIGNAL L62 18BR/RD
36
POWER MIRROR FOLD RELAY P171 20VT/WT
LEFT TURN SIGNAL L63 18DG/RDRED BRAKE WARNING LAMP DRIVER G9 20GY/BKFUSED IGNITION SWITCH OUTPUT (RUN-ACC)
JUNCTION BLOCK - C2
- - FUSED B(+) F20 18WT F20 20WT FUSED B(+)
FUSED IGNITION SWITCH OUTPUT F20 20WT
L62 18BR/RD RIGHT TURN SIGNAL L9 18BK/WT
FUSED FLASHER FEED
LEFT TURN SIGNAL - - FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
- - - - - - - -
DOME LAMP FEED M113 20LB/PK FUSED IGNITION SWITCH OUTPUT F55 12TN/DGFUSED IGNITION SWITCH OUTPUT F20 20WT
L61 18LG LEFT TURN SIGNAL F1 20DB
Z1 14BK GROUND
36 29 22 18 147
30 23 19 158 1 GRAY
L60 18TN
A22 12BK/OR M11 20PK/LB M11 20PK/LB L63 18DG/RD
F21 16TN L97 18PK/DB
V10 20BR C40 12BR/WT* F45 20YL/RD
F55 12TN/DG F1 20DB
F41 20PK/VT F41 20PK/VT F20 20WT F1 20DB
M11 20PK/LB X4 20GY/OR G9 20GY/BK
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 RIGHT TURN SIGNAL
IGNITION SWITCH OUTPUT (RUN)
FUSED IGNITION SWITCH OUTPUT PARK LAMP RELAY CONTROL
WASHER PUMP CONTROL SWITCH OUTPUT 5-VOLT SUPPLY FUSED B(+) ENGINE STARTER MOTOR RELAY
FUSED IGNITION SWITCH OUTPUT FUSED B(+)
FUSED B(+) FUSED B(+) FUSED IGNITION SWITCH OUTPUT COURTESY LAMP RELAY OUTPUT HORN RELAY CONTROL RED BRAKE WARNING LAMP DRIVER
- CIRCUIT
- FUNCTION
F133 20BR/YL** LOCK RELAY OUTPUT
F133 20BR/YL** LOCK RELAY OUTPUT
** GAS, EXCEPT BUILT-UP-EXPORT* REAR A/C
COURTESY LAMP RELAY OUTPUT
COURTESY LAMP RELAY OUTPUT
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
NSGS8045J988W-3

L91 20DB/PKFUSED IGNITION SWITCH OUTPUT X12 20RD/WT
FUSED B(+) F41 20PK/VT**
POWER MIRROR FOLD POWER MIRROR FOLD
P160 20LB** P160 20LB**
JUNCTION BLOCK - C3
- - - - - RIGHT TURN SWITCH SENSE L302 22LB/YLLEFT TURN SIGNAL L63 18DG/RD L62 18BR/RD RIGHT TURN SIGNAL L305 22LB/WT LEFT TURN SWITCH SENSE
- - - - - - - - - - - - - -
NAME BRAND SPEAKER RELAY DRIVER X60 20RD/DGRED BRAKE WARNING LAMP DRIVER G9 20GY/BK*
REAR WASHER MOTOR CONTROL V20 18RD
M11 20PK/LB X12 18RD/WT M112 22BR/LG
V10 20BR G9 20GY/BK
G9 20GY/BK
F41 20PK/VT
F41 20PK/VT
FUSED IGNITION SWITCH OUTPUT COURTESY LAMP RELAY CONTROL
WASHER PUMP CONTROL SWITCH OUTPUT RED BRAKE WARNING LAMP DRIVER
RED BRAKE WARNING LAMP DRIVER
FUSED B (+)
FUSED B(+)
L93 22PK L91 22DB/PK
M113 20LB/PK
A31 12BK/WT
M111 22BR/WT HIGH BEAM RELAY CONTROL READING LAMP FEED
IGNITION SWITCH OUTPUT (RUN-ACC)
SWITCHED COURTESY LAMP RELAY CONTROL 36 23 22 15 141
30 29 19 188
7 GRAY
F1 20DB A22 12BK/OR
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 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) IGNITION SWITCH OUTPUT (RUN)
- - CIRCUIT
- - FUNCTION
RHD GAS
GAS, EXCEPT BUILT-UP-EXPORT
* LHD
** BUILT-UP-EXPORT L63 18DG/RD LEFT TURN SIGNAL
G9 20GY/BK RED BRAKE WARNING LAMP DRIVER
COURTESY LAMP RELAY OUTPUT
COMBINATION FLASHER SWITCHES GROUND COMBINATION FLASHER SWITCHES GROUND
8W - 80 - 46 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8046

(LHD) MESSAGE CENTER
* DIESEL WAIT-TO START WARNING LAMP DRIVER G85 20OR/BK * 7
BLUE
7 1
136
G69 22BK/OR M1 20PK
R41 18BK/TN V23 18BR/PK G9 20GY/BK
G6 22GY G3 20BK/PK G2 22VT
G19 20LG/OR L62 18BR/RD Z1 20BK
L63 18DG/RD L34 20RD/OR
13 12 11 10 9 8 7 6 5 4
3 2 1 CAV VTSS INDICATOR LAMP DRIVER
FUSED B (+)
AIRBAG WARNING LAMP DRIVER FUSED IGNITION (ST-RUN) RED BRAKE WARNING LAMP DRIVER
ENGINE OIL PRESSURE SWITCH SENSE SERVICE ENGINE SOON INDICATOR LAMP DRIVER ENGINE TEMPERATURE WARNING LAMP DRIVER
ABS WARNING LAMP DRIVER RIGHT TURN SIGNAL GROUND
LEFT TURN SIGNAL FUSED HIGH BEAM RELAY OUTPUT CIRCUIT
FUNCTION
SWITCH MEMORY SET
BLUE564
1 2 3
P23 20PK/RD P22 20PK/BK P24 20PK/WT Z1 20BK
6 5 4 3 2
1 CAV MEMORY NO. 2 MEMORY SET MEMORY NO. 1 GROUND - - CIRCUIT
- - FUNCTION
MODULE - C3 MEMORY SEAT/MIRROR
21 10
11 NATURAL
1
P29 20BR/WT P25 22VT/RD P47 22LB P40 22GY/LB P15 22YL/LB
P11 22YL/WT P19 22YL/LG P9 20RD
P28 20BR/RD P26 22BR P27 22LB/RD P48 22GY/WT P17 22RD/LB P13 22RD/WT
P21 22RD/LG
21 20 19
18 17 16
15 14 13
12 11 10 9 8 7
6
5 4 3
2 1 CAV 6 VOLT SUPPLY SEAT HORIZONTAL POSITION SENSE SEAT RECLINER POSITION SENSE SEAT RECLINER (FORWARD) SEAT HORIZONTAL (FORWARD) SEAT REAR VERTICAL (UP) SEAT FRONT VERTICAL (UP)
FUSED B (+) SEAT POSITION SENSE COMMON SEAT FRONT VERTICAL POSITION SENSE SEAT REAR VERTICAL POSITION SENSE SEAT RECLINER (REARWARD) SEAT HORIZONTAL (REARWARD)
SEAT REAR VERTICAL (DOWN)
SEAT FRONT VERTICAL (DOWN)
- - - - - - CIRCUIT
- - - - - - - FUNCTION
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTSNS/GS
J988W-3NSGS8058

SWITCH MULTI-FUNCTION
8 127BLACK
1
L324 22WT/LG V10 20BR
L94 20OR/WT L93 22PK Z1 18BK
F1 20DB V52 20DG//YL V16 20WT
L305 22LB/WT L302 22LB/YL L91 22DB/PK
12 11 10 9 8 7
6
5 4 3 2 1 CAV HIGH BEAM RELAY CONTROL
FRONT WASHER MOTOR CONTROL LOW BEAM RELAY CONTROL HIGH/LOW BEAM RELAY CONTROL
GROUND FUSED B(+) WIPER MUX SIGNAL
HIGH SPEED RELAY DRIVER RIGHT TURN SIGNAL SENSE LEFT TURN SIGNAL SENSE COMBO FLASHER SWITCHED GROUND
- CIRCUIT
- FUNCTION
ACTUATOR MODE DOOR
5BLACK1
C35 20DG/YL C57 20DB/GY C37 20YL
C26 20PK/DB
C34 20DB/WT
5 4
3 2 1 CAV MODE DOOR DRIVER SENSOR GROUND MODE DOOR FEEDBACK SIGNAL
5 VOLT SUPPLY DOOR COMMON CIRCUIT
FUNCTION
FUSED RIGHT HIGH BEAM OUTPUT L34 20RD/OR7 131 6ENGINE TEMPERATURE WARNING LAMP DRIVER CIRCUIT FUNCTION
CAV
G2 22VT
1
2G19 20LG/OR
3L63 18DG/RD LEFT TURN SIGNAL
6L62 18BR/RD RIGHT TURN SIGNALSGROUND Z1 20BK
54
G69 22BK/OR
7
8M1 20PK
9R41 18BK/OR
V23 18BR/PK
10
13G3 20BK/PKENGINE OIL PRESSURE SWITCH SENSE G6 22GY
12G9 20GY/BK RED BRAKE WARNING LAMP DRIVER
11ABS WARNING LAMP DRIVER
FUSED B(+)
FUSED IGNITION (ST-RUN)
(RHD) MESSAGE CENTER
VTSS INDICATOR LAMP DRIVER
AIRBAG WARNING LAMP DRIVER
SERVICE ENGINE SOON INDICATOR LAMP DRIVER
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59
NSGS8059J988W-3

CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, these
steps should be used.
CAUTION: Do Not Use Starter Motor To Rotate
Engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.)
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter.
(11) Connect negative battery cable.
(12) Start engine and check for any leaks.
ENGINE OIL
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. For 2.4L, 3.3L and 3.8L engines, maintain
the oil level between the MIN and MAX markings on
the dipstick. Adding one quart of oil when the read-ing is at the MIN mark will result in a MAX reading
on these engines. For the 3.0L engine, add one full
quart when the level on the dipstick is at or below
the ADD mark.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
NSENGINE 9 - 5
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION
PRESSURE LEAKAGE TEST.............. 8
CYLINDER COMPRESSION PRESSURE TEST . . 7
ENGINE DIAGNOSISÐMECHANICAL......... 12
ENGINE DIAGNOSISÐPERFORMANCE...... 10GENERAL INFORMATION.................. 7
INSPECTION
(ENGINE OIL LEAKS IN GENERAL)......... 8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS..... 7
LASH ADJUSTER (TAPPET)
NOISE DIAGNOSIS...................... 8
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System, for the fuel system diag-
nosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If a change in RPM'S, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
(7) Repeat the previous step for all remaining cyl-
inders.
(8) Compression should not be less than (689kPa)
100 psi and not vary more than 25 percent from cyl-
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
NSENGINE 9 - 7

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and disassem-
bleDo not reuse retainer caps. Do not inter-
change parts and make sure that care and
cleanliness is exercised in the handling of parts.
c. Clean out dirt and varnish with solvent.
d. Reassemble with engine oil.
e. Check for sponginess.
f. If still spongy, replace with new adjuster.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
9 - 8 ENGINENS
DIAGNOSIS AND TESTING (Continued)