service CHRYSLER VOYAGER 1996 Service Manual

POWERTRAIN
CONTROL
MODULE
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
K20
18
DG
8C1
2
GENERATOR
7
ST-RUN V23
CENTER MESSAGESERVICE
ENGINE
SOON
LAMP
C1225
B70
E43
P34
B232
A2G3
20
BK/PK
BK/PK20 G3
BK/PK18 G3
LAMP DRIVER SOON INDICATORENGINESEVICE
DRIVERFIELD GENERATOR *13
* RHD RHD LHD
JUNCTION
BLOCK
TOZ1
20
BK
GENERATOR
FIELD
DRIVER
(8W-33-3) (8W-33-3)
(8W-15-7)(8W-20-2) (8W-12-9)
(8W-46-3)
(8W-12-19)
NS/GS8W-30 FUEL/IGNITION SYSTEM
2.0L8W - 30 - 13
GS003013J988W-3

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

8W-46 MESSAGE CENTER
Component Page
A/C Heater Control..................8W-46-2, 3
ABS Warning Lamp...................8W-46-2
Airbag Control Module.................8W-46-2
Airbag Warning Lamp..................8W-46-2
Body Control Module...............8W-46-2, 4, 5
Brake Pressure Switch.................8W-46-3
Brake Warning Lamp..................8W-46-3
Combination Flasher/DRL Module.....8W-46-3, 4, 5
Controller Anti-Lock Brake..............8W-46-2
Engine Coolant Temperature Lamp........8W-46-2
Engine Oil Pressure Switch..............8W-46-2
Fuse 5 (PDC).........................8W-46-4
Fuse 6 (JB)........................8W-46-2, 3
Fuse 28 (PDC)........................8W-46-2
G200...........................8W-46-3, 4, 5
G300...........................8W-46-3, 4, 5
Glow Plug Lamp......................8W-46-3
Headlamp Dimmer Switch..............8W-46-4
High Beam Indicator...................8W-46-4Component Page
High Beam Relay.....................8W-46-4
Ignition Switch.......................8W-46-3
Junction Block..................8W-46-2, 3, 4, 5
Left Rear Lamp Assembly...............8W-46-5
Left Repeater Lamp...................8W-46-5
Left Turn Indicator....................8W-46-5
Low Beam Relay......................8W-46-4
Low Oil Pressure Lamp.................8W-46-2
Memory Seat/Mirror Module.............8W-46-2
Message Center.................8W-46-2, 3, 4, 5
Park Brake Switch....................8W-46-3
Power Distribution Center.............8W-46-2, 4
Powertrain Control Module..............8W-46-3
Remote Keyless Entry Module...........8W-46-2
Right Rear Lamp Assembly..............8W-46-5
Right Repeater Lamp..................8W-46-5
Right Turn Indicator...................8W-46-5
Service Engine Soon Lamp..............8W-46-3
Turn Signal/Hazard Switch..............8W-46-5
VTSS Lamp..........................8W-46-2
NS/GS8W - 46 MESSAGE CENTER 8W - 46 - 1

(ST-RUN) IGNITIONFUSED
GY/BK20 G9
Z1
20
BK
14
G200
IGNITION
SWITCH
4 1
2
03
2C1
1C1
BK20Z1
G300
9
SWITCH PRESSURE
BRAKE
B
1C2
A
G9
20
GY/BK
GY/BK20 G9
PARK
BRAKE
SWITCH
C39
C38
G9
20
GY/BK
JUNCTION
BLOCK
9
BRAKE
WARNING
LAMP
BK/PK20 G3
BK/PK20 G3
5B70
E43
2
DRIVERLAMP 22
SERVICE
ENGINE
SOON
MODULE CONTROL
POWERTRAIN
C1
LAMP
SOON
ENGINE
SERVICE
7
CENTER
MESSAGE
10
ST-RUN A21
20A
FUSE
6
BLOCK JUNCTION
14C4
BR/PK18 V23
C110
A/C
CONTROL
V23
18
BR/PK
A2
HEATER
GLOW
PLUG
LAMP
7
G85
20
OR/BK
POWERTRAIN
CONTROL
MODULE
26
GLOW
PLUG
LAMP
DRIVER GAS DIESEL
A17
17P34
B23
OR/BK20 G85
10
MODULE DRL
FLASHER/
COMBINATION
BRAKE
LAMP
SENSE
MTX
1 START
2 RUN
3 LOCK 0 OFF
4 ACC *13 *11
G3
18
BK/PK
EATX
8C2
* RHD
INDICATOR
(8W-15-4) (8W-15-8)(8W-12-2)
(8W-30-13)
(8W-30-19)
(8W-30-27)(8W-12-9)(8W-10-16)
(8W-12-2)
(8W-42-4)
(8W-30-32)(8W-50-13)
(8W-10-14)
NS/GS8W-46 MESSAGE CENTER 8W - 46 - 3
GS004603J988W-3

(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

MODULE - C1CONTROL POWERTRAIN
- -
K90 18TN ENGINE STARTER MOTOR RELAY CONTROL
C103 18DG/LB A/C SWITCH SIGNALKNOCK SENSOR SIGNAL K42 18DB/LG- - BLACK
10 20 30 40
1 11 21 31
K35 18GY/YL K1 18DG/RD K22 18OR/DB K44 18TN/YL K24 18GY/BK K41 18BK/DG K2 18TN/BK G3 18BK/PK F87 18WT/BK K12 18TN/WT K14 18LB/BR
K38 18GY K58 18BR/DB K11 18WT/DB K19 18GY/RD Z12 18BK/TN K20 18DG K13 18YL/WT
A142 18DG/OR V32 18YL/RD K17 18DB/TN K18 18RD/YL
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 EGR SOLENOID CONTROL MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL THROTTLE POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR SIGNAL CRANKSHAFT POSITION SENSOR SIGNAL HEATED OXYGEN SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SERVICE ENGINE SOON INDICATOR LAMP DRIVER FUSED IGNITION SWITCH OUTPUT (ST-RUN) INJECTOR NO. 2 DRIVER INJECTOR NO. 4 DRIVER
INJECTOR NO. 5 DRIVER (3.3L/3.8L) INJECTOR NO. 6 DRIVER (3.3L/3.8L) INJECTOR NO. 1 DRIVER IGNITION COIL NO. 1 DRIVER GROUND GENERATOR FIELD DRIVER INJECTOR NO. 3 DRIVER
AUTOMATIC SHUT DOWN RELAY OUTPUT SPEED CONTROL ON/OFF SWITCH SENSE IGNITION COIL NO. 2 DRIVER IGNITION COIL NO. 3 DRIVER (3.3L/3.8L)
- - - - - - -
- - - - - CIRCUIT
- - - - - - -
- - - - - FUNCTION
K21 18BK/RD* INTAKE AIR TEMPERATURE SENSOR SIGNAL
* 2.0L
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71
NSGS8071J988W-3

ENGINE
CONTENTS
page page
2.4L ENGINE............................ 14
3.0L ENGINE............................ 61
3.3/3.8L ENGINE........................ 93ENGINE DIAGNOSIS....................... 7
STANDARD SERVICE PROCEDURES.......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION
CRANKSHAFT SPROCKET BOLT ACCESS
PLUG................................ 2
ENGINE CORE PLUGS.................... 2
ENGINE OIL SERVICE..................... 5
ENGINE OIL............................. 5
ENGINE PERFORMANCE.................. 2FORM-IN-PLACE GASKETS................. 1
HONING CYLINDER BORES................ 3
HYDROSTATIC LOCKED ENGINE............ 5
MEASURING MAIN BEARING AND
CONNECTING ROD BEARING
CLEARANCES......................... 3
REPAIR OF DAMAGED OR WORN THREADS . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets.Do not use
form-in-place gasket material unless specified.
Bead size, continuity, and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over, a continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine.MopartSilicone Rubber Adhe-
sive Sealant andMopartGasket Maker, (anaerobic)
each have different properties and cannot be used
interchangeably.
CAUTION: Silicone sealer and anaerobic sealers
each will inhibit the cure of the other and care
should be taken to keep usages separated as much
as possible.
MOPARTSILICONE RUBBER ADHESIVE
SEALANT
MopartSilicone Rubber Adhesive Sealant or
equivalent, normally black in color, is available in
three ounce tubes. Moisture in the air causes the
MopartSilicone Rubber Adhesive Sealant material
to cure. This material is normally used on flexible
metal flanges. It has a shelf life of one year and will
not properly cure if over age. Always inspect the
package for the expiration date before use.
MOPARTGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material normally red in color. The material cures in
the absence of air when squeezed between two metal-
lic surfaces. It will not cure if left in the uncovered
tube. It is normally red in color. The anaerobic mate-
rial is for use between two machined surfaces. Do not
use on flexible metal flanges.
MOPARTTORQUE CURE GASKET MAKER
MopartTorque Cure Gasket Maker is a unique
anaerobic type gasket material to be usedONLY
between the bedplate and engine block. The material
cures in the absence of air when torqued between
two metallic surfaces. It will not cure if left in the
uncovered tube. This anaerobic material is specially
NSENGINE 9 - 1

made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
TheMopartSilicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3 mm (0.120 in.) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop
is placed in the center of the gasket contact area.
Uncured sealant may be removed with a shop towels.
Components should be torqued in place while the
sealant is still wet to the touch (within 10 minutes).
The usage of a locating dowel is recommended during
assembly to prevent smearing of material off loca-
tion.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmlywith pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at
least 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINENS
GENERAL INFORMATION (Continued)