fuel cap CHRYSLER VOYAGER 1996 Owner's Manual

(11) Using Special Tool 6856, remove plastic lock-
nut counterclockwise to release pump module (Fig.
16).
(12) Carefully remove pump module and O-ring
from tank (Fig. 17).
(13) Discard old O-ring.INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump in tank with locknut.
(3) Tighten locknut to 53 N´m (43 ft. lbs.).
(4) Connect fuel lines.
(5) Plug in electrical connector. Slide connector
lock into position.
(6) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(7) Lower vehicle on hoist.
(8) Connect negative cable from battery.
(9) Fill fuel tank. Check for leaks.
(10) Install fuel filler cap.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is part of the fuel
pump module (Fig. 18). Remove the fuel pump mod-
ule from the fuel tank to access the fuel pressure reg-
ulator.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Spread tangs on pressure regulator retainer
(Fig. 18).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
(1) Lightly lubricate the O-rings with clean engine
oil and place them into opening in pump module (Fig.
19).
(2) Push regulator into opening in pump module.
Fig. 16 Fuel Pump Module Lock Nut Removal
Fig. 17 Fuel Pump Module Removal
Fig. 18 Fuel Pressure Regulator
14 - 14 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL TANK
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist.
(6) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank.(7) Disconnect fuel supply lines from the steel sup-
ply line.
The fuel pump module electrical connector
has a retainer that locks it in place.
(8) Slide fuel pump module electrical connector
lock to unlock (Fig. 29).
(9) Push down on connector retainer (Fig. 30) and
pull connector off module.
(10) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(11) Lower tank slightly. Carefully remove filler
hose from tank.
(12) Lower the fuel tank. Disconnect pressure
relief/rollover valve hose at the front of tank. Remove
clamp and remove fuel filler tube vent hose. Remove
fuel tank from vehicle.
Fig. 28 Installation Channel
Fuel Tank
Fig. 29 Fuel Line Retainers and Pump Connector
Lock
Fig. 30 Pump Module Connector Retainer and Lock
NSFUEL SYSTEM 14 - 17
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect pressure relief/rollover valve hose. Connect fuel
filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this Group.
(8) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(9) Fill fuel tank, replace cap, and connect battery
negative cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(10) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL INJECTOR RAILÐ2.4L
REMOVAL
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove air cleaner inlet hose from throttle
body.
(4) Remove throttle cable and speed control cable
(if equipped) from throttle lever.
(5) Remove throttle cables from bracket by com-
pressing retaining tabs.
(6) Remove connector from throttle position sensor.
(7) Remove connector from idle air control motor.
(8) Remove vacuum lines from intake plenum fit-
tings (Fig. 31) and (Fig. 32).(9) Remove connector from intake air temperature
sensor (Fig. 32).
(10) Remove connector from MAP sensor (Fig. 33).
(11) Remove fuel hose quick connect fitting from
the chassis tube (Fig. 34).Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in this Sec-
tion.Place a shop towel under the connections to
absorb any fuel spilled from the fitting.
Fig. 31 Vacuum Fitting on Rear of Intake Manifold
Fig. 32 Electrical and Vacuum Connections
14 - 18 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque (Fig. 51).
(5) Install fuel tube retaining bracket screw.
Tighten screw to 4 N´m (35 in. lbs.) torque.
(6) Connect electrical connectors to camshaft posi-
tion sensor and engine coolant temperature sensor.
(7) Remove covering on lower intake manifold and
clean surface.
(8) Place intake manifold gasket on lower mani-
fold. Put upper manifold into place and install bolts
finger tight.
(9) Install the generator bracket to intake mani-
fold bolt and the cylinder head to intake manifold
strut bolts (do not tighten.)(10) Following the tightening sequence in (Fig. 50),
tighten intake manifold bolts to 28 N´m (250 in. lbs.)
torque.
(11) Tighten generator bracket to intake manifold
bolt to 54 N´m (40 ft. lbs.) torque.
(12) Tighten the cylinder head to intake manifold
strut bolts to 54 N´m (40 ft. lbs.) torque.
(13) Connect ground strap and MAP sensor electri-
cal connector.
(14) Connect vacuum harness to intake plenum.
Connect PCV system hoses.
(15) Using a new gasket, connect the EGR tube to
the intake manifold plenum. Tighten screws to 22
N´m (200 in. lbs.) torque.
(16) Connect electrical connectors to the TPS and
idle air control motor.
(17) Connect vacuum harness to throttle body.
(18) Install the direct ignition system (DIS) coils.
Tighten fasteners to 12 N´m (105 in. lbs.) torque.
(19) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(20) Install throttle cable and speed control cable
(if equipped).
(21) Install air inlet resonator.
(22) Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(23) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
FUEL INJECTORÐ2.4L
The fuel rail must be removed first. Refer to Fuel
Injector Rail Removal in this section.
REMOVAL
(1) Disconnect injector wiring connector from injec-
tor.
(2) Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 54).
(3) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is dam-
aged.
(5) Repeat for remaining injectors.
Fig. 52 Camshaft Position Sensor Connector
Fig. 53 Fuel Rail Removal
14 - 24 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip.
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 55).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
FUEL INJECTORSÐ3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Release Procedure.
(2) Disconnect negative cable from battery.
(3) The fuel rail must be removed first to service
the injectors. Refer to Fuel Injector Rail Assembly
Removal in this section.
(4) Label each injector connector with its cylinder
number. Disconnect electrical connector from injector.
(5) Position fuel rail assembly so that the fuel
injectors are easily accessible.
(6) Remove injector clip from fuel rail and injector
(Fig. 54).
(7) Pull injector straight out of fuel rail receiver
cup (Fig. 55).
(8) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is to be
reused, a protective cap must be installed on the
injector tip to prevent damage.
(9) Repeat procedure for remaining injectors.
INSTALLATION
(1) Before installing an injector, the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Being careful not to damage O-ring, install
injector nozzle end into fuel rail receiver cap.
(3) Install injector clip by sliding open end into
top slotof the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 55)
(4) Repeat steps for remaining injectors.
(5) Install fuel rail assembly. Refer to Fuel Rail
Assembly Installation in this section.
(6) Connect electrical connectors to injectors in cor-
rect order.
(7) Connect negative battery cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(8) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
Fig. 54 Fuel Injector and RailÐTypical
Fig. 55 Servicing Fuel InjectorÐTypical
NSFUEL SYSTEM 14 - 25
REMOVAL AND INSTALLATION (Continued)

FUEL INJECTORÐ3.3/3.8L
The fuel rail must be removed first. Refer to Fuel
Injector Rail Assembly Removal in this section.
REMOVAL
(1) Disconnect injector wiring connector from injec-
tor.
(2) Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 54).
(3) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is dam-
aged.
(5) Repeat for remaining injectors.
INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 56).
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 56).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Working from the engine compartment, remove
the throttle control shield.
(2) Hold the throttle body throttle lever in the
wide open position. Remove the throttle cable from
the throttle body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 57) and (Fig. 58).
(4) Working from the engine compartment, remove
nuts from accelerator pedal attaching studs (Fig. 57).
Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts
to 12 N´m (105 in. lbs.) torque.
Fig. 56 Servicing Fuel InjectorÐTypical
Fig. 57 Accelerator Pedal and Throttle CableÐFront
View
Fig. 58 Accelerator Pedal and Throttle CableÐRear
View
14 - 26 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Fuel Pump Module Locknut.....58N´m(43ft.lbs.)
Fuel Tank Strap Bolts.........54N´m(40ft.lbs.)
Fuel Rail BoltsÐ2.4L........22N´m(200 in. lbs.)
Fuel Rail BoltsÐ3.0L.........13N´m(115in.lbs.)
Fuel Rail BoltsÐ3.3/3.8L.......10N´m(95in.lbs.)
Fuel Tube Holddown BoltsÐ3.0L..........22N´m
(200 in. lbs.)
Fuel Tube Holddown Screw......4N´m(35in.lbs.)
Intake Manifold BoltsÐ2.4L . . .22 N´m (200 in. lbs.)
Intake Manifold BoltsÐ3.0L . . .13 N´m (115 in. lbs.)
Intake Manifold BoltsÐ3.3/3.8L...........28N´m
(250 in. lbs.)
Accelerator Pedal to Dash Nuts...........12N´m
(105 in. lbs.)
FUEL TANK CAPACITY
Vehicle Liters U.S. Gallons
NS 75.O 20
Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
14 - 28 FUEL SYSTEMNS

circuit information. If the resistance is greater than 1
ohm, repair the wire harness as necessary.
THROTTLE POSITION SENSOR
To perform a complete test of the this sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the throttle position sensor only, refer to the fol-
lowing:
The Throttle Position Sensor (TPS) can be tested
with a digital voltmeter (DVM). The center terminal
of the sensor is the output terminal. One of the other
terminals is a 5 volt supply and the remaining ter-
minal is ground.
Connect the DVM between the center and sensor
ground terminal. Refer to Group 8W - Wiring Dia-
grams for correct pinout.
With the ignition switch in the ON position, check
the output voltage at the center terminal wire of the
connector. Check the output voltage at idle and at
Wide-Open-Throttle (WOT). At idle, TPS output volt-
age should be approximately 0.38 volts to 1.2 volts.
At wide open throttle, TPS output voltage should be
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Warm engine in Park or Neutral until the cool-
ing fan has cycled on and off at least once.
(2) Ensure that all accessories are off.
(3) Shut off engine.
(4)3.0L Engine
(a) Hook-up the timing check device and tachom-
eter.(b) Disconnect the engine coolant temperature
sensor and set basic timing to 12É BTDC62É.
(c) Shut off engine. Reconnect coolant tempera-
ture sensor wire.
(5) Disconnect the PCV valve hose from the intake
manifold nipple (Fig. 101), (Fig. 102) or (Fig. 103).
(6) Cap the PCV valve nipple.
(7)3.3/3.8L Engines
(a) Install Air Metering Fitting 6457 (0.125 in.
orifice) to the intake manifold PCV nipple (Fig.
100).
(b) Disconnect the idle purge line from the throt-
tle body nipple.
(8)3.0/2.4L Engines
(a) Install Air Metering Fitting 6457 (0.125 in.
orifice) to the purge nipple on the throttle body.
(9)3.3/3.8L Engines
(a) Cap the 3/16 inch nipple.
(b) Connect the DRB scan tool to the data link
connector.
(10) Restart the engine. Allow engine to idle until
the cooling fan has cycled on and off at least one
180ÉF cycle.
(11) Using the DRB scan tool, access the Minimum
Airflow Idle Speed screen.
(12) The following will then occur:
²Idle air control motor will fully close.
²Idle spark advance will become fixed.
²DRB scan tool displays engine rpm.
(13) If idle rpm is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
IDLE SPECIFICATIONSÐ2.4L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................500-875 RPM
Above 1000 Miles.................550±875 RPM
Fig. 99 Engine Coolant Temperature Sensor
Fig. 100 Air Metering Fitting 6457
14 - 62 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

IDLE SPECIFICATIONSÐ3.0L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................560-910 RPM
Above 1000 Miles.................610-910 RPM
IDLE SPECIFICATIONSÐ3.3/3.3L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................525±875 RPM
Above 1000 Miles.................575±875 RPM
(14) If idle rpm is not within specifications, shut
off the engine and clean the throttle body as follows:
(a) Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(b) While holding the throttle open, spray the
entire throttle body bore and the manifold side of
the throttle plate with Mopar Parts Cleaner.Only
use Mopar Parts Cleaner to clean the throttle
body.
(c) Using a soft scuff pad, clean the top and bot-
tom of throttle body bore and the edges and mani-
fold side of the throttle blade.The edges of the
throttle blade and portions of the throttle
bore that are closest to the throttle blade
when closed, must be free of deposits.
(d) Use compressed air to dry the throttle body.
(e) Inspect throttle body for foreign material.
(f) Install throttle body on manifold.
(g) Repeat steps 1 through 12. If the minimum
air flow is still not within specifications, the prob-
lem is not caused by the throttle body.
(15) Shut off engine.
(16) Remove Air Metering Fitting 6457 from the
intake manifold PCV nipple. Reinstall the PCV valve
hose.
(17) Uncap the throttle body idle purge nipple and
connect the idle purge line.
(18) Remove DRB scan tool.
Fig. 101 PCV ValveÐ2.4L Engine
Fig. 102 PCV ValveÐ3.0L Engine
Fig. 103 PCV ValveÐ3.3/3.8L Engines
NSFUEL SYSTEM 14 - 63
DIAGNOSIS AND TESTING (Continued)

FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE
CONTENTS
page page
FUEL DELIVERY SYSTEMÐ2.0L ENGINE.... 28
FUEL DELIVERY SYSTEMÐ2.5L DIESEL
ENGINE.............................. 3
FUEL INJECTION SYSTEMÐ2.0L ENGINE . . . 32FUEL INJECTION SYSTEMÐ2.5L DIESEL
ENGINE............................. 43
GENERAL INFORMATION.................. 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTSÐ2.0L ENGINE....... 2
FUEL REQUIREMENTSÐ2.5L DIESEL........ 2GASOLINE/OXYGENATE BLENDS........... 2
INTRODUCTIONÐ2.0L ENGINE............. 2
INTRODUCTIONÐ2.5L DIESEL............. 1
GENERAL INFORMATION
INTRODUCTIONÐ2.5L DIESEL
Certain components of the fuel system on the 2.5L
diesel engine are controlled by the Bosch Engine con-
troller which is a Powertrain Control Module (PCM).
Refer to Powertrain Control Module in the Fuel
Injection SystemÐ2.5L Diesel Engine section of this
group for a list of items controlled by the PCM. The
Body Control Module (BCM) is mounted to a bracket
located inside the vehicle under the dashpanel to the
left of the steering column (Fig. 1). The PCM is
mounted at the base of the center console in front of
the Air Bag Module. (Fig. 2).
TheFuel Systemconsists of: the fuel tank, fuel
injection pump (engine mounted), fuel filter/water
separator, fuel tank module, electrical fuel gauge
sending unit, glow plugs, glow plug relay, PCM, and
all the electrical components that control the fuel
system. It also consists of fuel tubes/lines/hoses and
fittings, vacuum hoses, and fuel injector(s).
AFuel Return System.A separate fuel return
system is used. This will route excess fuel: from the
fuel injectors; through individual injector drain
tubes; through the fuel injection pump overflow
valve; and back to the fuel tank through a separate
fuel line.TheFuel Tank Assemblyconsists of: the fuel
tank, two pressure relief/rollover valves, fuel filler
tube, fuel tank module containing a fuel gauge send-
ing unit, and a pressure-vacuum filler cap.
Fig. 1 BCM Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 1