tow bar CHRYSLER VOYAGER 1996 User Guide

(7) Remove the wheel speed sensor cable grommets
from the retaining bracket (Fig. 37).(8) Remove front wheel speed sensor assembly
from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts
and/or over extension of cables, resulting in an
open circuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector (Fig. 35). Be
sure speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then
insert cable and grommet into hole in strut tower
(Fig. 35).
CAUTION: When installing channel bracket, do not
pinch the speed sensor cable under the channel
bracket.
(2) Install the channel bracket and grommet
retainer on the frame rail (Fig. 34).
(3) Install the 2 bolts (Fig. 34) attaching the chan-
nel bracket to frame. Tighten the 2 attaching bolts to
a torque of 11 N´m (95 in. lbs.).
(4) Insert speed sensor cable grommets into inter-
mediate bracket on strut (Fig. 37). Route cable from
strut to steering knuckle on the rearward side of the
stabilizer bar link.
(5) Install the wheel speed sensor to steering
knuckle attaching bolt (Fig. 36). Tighten the speed
sensor attaching bolt to a torque of 12 N´m (105 in.
lbs.)
(6) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone-
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 in.).
(7) Install the wheel and tire assembly on vehicle.
(8) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
WHEEL SPEED SENSOR (REAR FWD)
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove the tire and wheel assembly from the
vehicle.
Fig. 35 Speed Sensor Cable To Vehicle Wiring
Harness
Fig. 36 Front Wheel Speed Sensor Attaching Bolt
Fig. 37 Front Wheel Speed Sensor Cable Routing
5 - 106 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
DESCRIPTION AND OPERATION
HVAC MOUNTED SWITCH................. 1
INTRODUCTION......................... 1
DIAGNOSIS AND TESTING
GRID LINE TEST......................... 2SYSTEM TEST.......................... 2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR......... 3
DESCRIPTION AND OPERATION
INTRODUCTION
The electrically heated Rear Window Defogger (Fig.
1), Heated Power Side View Mirrors, and Heated
Windshield Wiper De-icer (Fig. 2) is available on NS
vehicles.
The Rear Window Defogger system consists of two
vertical bus bars linked by a series of grid lines on
the inside surface of the rear window. The electrical
circuit consists of the rear defogger switch in the
HVAC and a relay with timer switch to turn OFF the
system after ten minutes. The main feed circuit is
protected by fuse one (40 amp) in the Junction Block.
The rear defogger switch and relay also activates the
heated power side view mirrors and heated wind-
shield wiper de-icer. The HVAC rear defogger switch
is protected by fuse ten (10 amp) in the Junction
Block. The heated mirror circuit is protected by fuse
12 (10 amp) in the junction block. The heated wind-
shield wiper de-icer circuit is protected by fuse 21 (25
amp) in the Junction Block.
The Heated Windshield Wiper Deicer is also acti-
vated when the DEFROST mode is selected on the
HVAC. In the DEFROST mode the rear defogger
relay/timer is bypassed, the heated windshield wiper
de-icer will stay ON until the another mode is
selected. For circuit information and component loca-
tion refer to Group 8W, Wiring Diagrams.
CAUTION: Since grid lines can be damaged or
scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign
materials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is
recommended.
HVAC MOUNTED SWITCH
The rear window defogger switch is integrated into
the HVAC (Fig. 3). An LED indicator will illuminate
when the switch is activated. The switch energizesthe timing circuit and activates the rear window
defogger relay. The relay controls the current to flow
to the grids of the rear window defogger, heated
power side view mirrors and the heated windshield
wiper de-icer. The defogger relay will be on for
approximately 10 minutes or until the control switch
or ignition is turned off.
Fig. 1 Rear Window Defogger
Fig. 2 Heated Windshield Wiper De-icer
NSELECTRICALLY HEATED SYSTEMS 8N - 1

(3) With negative lead of voltmeter, contact a good
body ground point. The voltage reading should not
change. A different reading indicates a poor ground
connection.
(4) Connect negative lead of voltmeter to terminal
A on passenger side bus bar and touch each grid line
at Mid-Point with positive lead. A reading of approx-
imately 6 volts indicates a line is good. A reading of 0
volts indicates a break in line between Mid-Point C
and terminal B. A reading of 10-14 volts indicates a
break between Mid-Point C and ground terminal A.
Move toward break and voltage will change as soon
as break is crossed.
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING; CALL A PHYSICIAN
IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH
WITH PLENTY OF WATER. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR FLAME.
CONTENTS CONTAINS 3% FLAMMABLE SOL-
VENTS. KEEP OUT OF REACH OF CHILDREN.
The repair for the front windshield or the rear win-
dow grids are the same.
The repair of grid lines and replacement of the ter-
minal is possible using the MopartRepair Package
or equivalent.
(1) Clean area surrounding grid line or terminal
by gently rubbing area with steel wool.
(2) Wipe area with clean cloth soaked in alcohol or
similar solvent. It is necessary that all contaminants
be removed from repair area.(3) Remove package separator clamp and mix plas-
tic conductive epoxy thoroughly.
(4) For grid line, mark off area to be repaired with
masking tape (Fig. 5).
(5) Apply conductive epoxy through slit in masking
tape. Overlap both ends of the break.
(6) For a terminal replacement, apply a thin layer
of epoxy to area where terminal was fastened.
(7) Apply a thin layer of epoxy on terminal and
place terminal on desired location. To prevent termi-
nal from falling off use a wooden wedge to secure it.
(8) Carefully remove masking tape from grid line.
CAUTION: Do not allow the laminated windshield
glass surface to exceed 82É C (180É F) or the glass
may fracture. The rear window glass surface should
not exceed 204É C (400É F).
(9) Allow epoxy to cure 24 hours at room tempera-
ture.
(10) After epoxy is properly cured remove wedge
from terminal and check the operation of the rear
window defogger.
Fig. 5 Grid Line Repair
NSELECTRICALLY HEATED SYSTEMS 8N - 3
DIAGNOSIS AND TESTING (Continued)

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)

INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder.
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place
(Fig. 21).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install water shield and door trim panel.
FRONT DOOR OUTER BELT MOLDING
REMOVAL
(1) Remove door trim panel.
(2) Roll door glass down.
(3) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
22).
(4) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove front door trim panel and water shield
as necessary to gain access to the outside door han-
dle.
(2) Roll door glass up.(3) Through access hole at rear of inner door
panel, disconnect vehicle theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push-in fasteners holding VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch.
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel (Fig. 23).
(10) Remove outside door handle from vehicle.
Fig. 21 Install Front Door Lock Cylinder
Fig. 22 Front Door Outer Belt Molding
Fig. 23 Front Door Outside Handle
NSBODY 23 - 33
REMOVAL AND INSTALLATION (Continued)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)