service CHRYSLER VOYAGER 1996 Service Manual

CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
REPLACEMENT PARTS
Many components in your Flexible Fuel Vehicle
(FFV) are designed to be compatible with ethanol.Always be sure that your vehicle is serviced with cor-
rect ethanol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
NSFUEL SYSTEM 14 - 3
GENERAL INFORMATION (Continued)

FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM.................. 4
FUEL INJECTORS........................ 5
FUEL LEVEL SENSOR..................... 5
FUEL PRESSURE REGULATOR.............. 5
FUEL PUMP MODULE..................... 4
FUEL TANK............................. 5
PRESSURE-VACUUM FILLER CAP........... 6
QUICK-CONNECT FITTINGS................ 6
DIAGNOSIS AND TESTING
FUEL INJECTORS........................ 9
FUEL LEVEL SENSOR..................... 9
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L..... 6
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L............... 11
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE............. 11
HOSES AND CLAMPS.................... 12QUICK-CONNECT FITTINGS............... 12
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL................... 26
FUEL FILTER........................... 12
FUEL INJECTOR RAILÐ2.4L............... 18
FUEL INJECTOR RAILÐ3.0L............... 19
FUEL INJECTOR RAILÐ3.3/3.8L............ 21
FUEL INJECTORSÐ3.0L.................. 25
FUEL INJECTORÐ2.4L................... 24
FUEL INJECTORÐ3.3/3.8L................. 26
FUEL LEVEL SENSOR.................... 15
FUEL PRESSURE REGULATOR............. 14
FUEL PUMP INLET STRAINER............. 15
FUEL PUMP MODULE.................... 13
FUEL TANK............................ 17
THROTTLE CABLE...................... 27
SPECIFICATIONS
FUEL TANK CAPACITY................... 28
TORQUE.............................. 28
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
The front wheel drive van uses a plastic fuel tank
located on the left side of the vehicle.
The Fuel Delivery System consists of: the electric
fuel pump module, fuel filter, tubes/lines/hoses, fuel
rail, and fuel injectors.
The in-tank fuel pump module contains the fuel
pump and pressure regulator. The pump is serviced
as part of the fuel pump module. Refer to Fuel Pump
Module.
The fuel filter is a replaceable in-line filter. The fil-
ter attaches to a bracket mounted on top of the fuel
tank. Refer to the Maintenance Schedules in the
Introduction section of this manual for recommended
fuel filter replacement intervals.
A returnless fuel system is used on all vehicles.
Fuel is returned through the fuel pump module and
back to the fuel tank. A separate fuel return line
from the tank to the engine is no longer used.
FUEL PUMP MODULE
The fuel pump module is installed in the top of the
fuel tank (Fig. 1). The fuel pump module contains the
following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer²Fuel pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
ELECTRIC FUEL PUMP
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The pump draws fuel through
a strainer and pushes it through the motor to the
outlet. The pump contains one check valve. The
Fig. 1 Fuel Pump Module
14 - 4 FUEL SYSTEMNS

check valve, in the pump outlet, maintains pump
pressure during engine off conditions. The fuel pump
relay provides voltage to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 635 kPa (95 psi). The
regulator adjusts fuel system pressure to approxi-
mately 338 kPa (49 psi).
FUEL PUMP ELECTRICAL CONTROL
Voltage to operate the electric pump is supplied
through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
RelayÐPCM Output.
ELECTRICAL PUMP REPLACEMENT
The electric fuel pump is not serviceable. If the
fuel pump or electrical wiring harness needs replace-
ment, the complete fuel pump module must be
replaced. Perform the Fuel System Pressure Release
procedure before servicing the fuel pump.
FUEL LEVEL SENSOR
The level sensor is attached to the side of the fuel
pump module. The level sensor consists of a float, an
arm, and a variable resistor. As the fuel level
increases, the float and arm move up. This decreases
the sending unit resistance, causing the fuel gauge
on the instrument panel to read full.
FUEL PRESSURE REGULATOR
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 338 kPa (49 psi), 3.3l uses approxi-
mately 379 kPa (55 psi). The fuel pressure regulator
contains a diaphragm, calibrated spring and a fuel
return valve. The spring pushes down on the dia-
phragm and closes off the fuel return port. System
fuel pressure reflects the amount of fuel pressure
required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids
(Fig. 2). The injector contains a pintle that closes off
an orifice at the nozzle end. When electric current is
supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel
to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a
hollow cone. The spraying action atomizes the fuel,
adding it to the air entering the combustion chamber.
The injectors are positioned in the intake manifold.
Fuel injectors are not interchangeable between
engines.The injectors are positioned in the intake manifold
with the nozzle ends directly above the intake valve
port (Fig. 3).
FUEL TANK
The fuel tanks of all Chrysler Motors built vehicles
are equipped with fuel and vapor controls that allow
the vehicle to pass a full 360É rollover without fuel
leakage.
Front Wheel Drive fuel delivery systems contain a
fuel tank rollover valve. The valve is mounted on top
of the fuel tank. The valve functions as a tank pres-
sure control valve while the vehicle is upright, but
contains a check valve that prevents fuel from escap-
ing from the fuel tank when the vehicle is turned
over.
The fuel filler cap acts as a pressure/vacuum relief
valve. When air pressure inside the fuel tank gets too
high or too low, the fuel filler cap opens to relieve the
difference in pressure.
An evaporation control system restricts fuel evapo-
ration into the atmosphere and reduces unburned
Fig. 2 Fuel Injector
Fig. 3 Fuel Injector LocationÐTypical
NSFUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)

hydrocarbons. Vapors from the fuel tank are collected
in a charcoal filled canister. The vapors are held in
the canister until the engine is operating. When the
engine is running, the vapors are drawn through the
intake manifold into the combustion chambers.
PRESSURE-VACUUM FILLER CAP
The loss of any fuel or vapor out of the filler neck
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum
release for all gas caps is between 0.97 and 2.0 kPa
(0.14 and 0.29 psi). The cap must be replaced by a
similar unit if replacement is necessary.
WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with
plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 4).
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 4). When the fuel tube
enters the fitting, the retainer locks the shoulder of
the nipple in place and the O-rings seal the tube.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.The fuel system operates at approximately 338 kPa
(49 psi), 3.3L uses approximately 379 kPa (55 psi).
Check fuel system pressure at the test port on the
fuel rail (Fig. 5) or (Fig. 6).
Fig. 4 Plastic Quick-Connect Fittings
Fig. 5 Fuel Pressure Test PortÐ2.4L
14 - 6 FUEL SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L
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.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove protective cap from fuel pressure test
port on fuel rail (Fig. 9) or (Fig. 10).
(4) Place open end of fuel pressure release hose,
tool number C-4799-1, into an approved gasoline con-
tainer. Connect other end of hose C-4799-1 to fuel
pressure test port (Fig. 11). Fuel pressure will bleed
off through the hose into the gasoline container. Fuel
gauge C-4799-B contains hose C-4799-1.
(5)Replace Pressure test port cap when fin-
ished doing pressure test.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE
(1) Remove the Fuel Pump relay from the Power
Distribution Center (PDC). For location of the relay,
refer to the label on the underside of the PDC cover.
(2) Start and run engine it stalls.
(3) Attemp restarting engine until it will no longer
run.(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unplug connector from any injector.
(6) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(7) Connect the other end of the jumper wire to
the positive side of the battery.
(8) Connect one end of a second jumper wire to the
remaining injector terminal.
CAUTION: Supplying power to an injector for more
than 4 seconds will permantely damage the injector.
Do not leave the injector connected to power for
more than 4 seconds.
Fig. 9 Fuel Pressure Test PortÐ2.4L
Fig. 10 Fuel Pressure Test PortÐ3.3/3.8L
Fig. 11 Releasing Fuel Pressure
NSFUEL SYSTEM 14 - 11

(9) Momentarily touch the other end of this
jumper wire to the negative terminal of the battery
for no more than 4 seconds.
(10) Place a rag or towel below the fuel line at the
quick connect to the rail.
(11) Disconnect the quick connect fitting to the
rail. Refer to Quick-Connect Fittings in this section.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in the PCM memory due to the
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to group 25, On-Board
Diagnostics.
HOSES AND CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 12).Do not rely upon the
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
FUEL FILTER
The fuel filter mounts to the top of the fuel tank.
The inlet and outlet tubes are permanently attached
to the filter (Fig. 13).
Fig. 12 Plastic Quick-Connect Fitting/Fuel Tube
Connection
14 - 12 FUEL SYSTEMNS
SERVICE PROCEDURES (Continued)

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING QUICK-CONNECT FIT-
TINGS AT FUEL FILTER. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Perform fuel system pressure release.
(2) Disconnect quick-connect fittings from fuel
pump module and chassis fuel supply tube. Refer to
Quick-Connect Fittings in this section.
(3) Remove filter retaining screw (Fig. 13) and
remove filter from tank.
INSTALLATION
(1) Install fuel filter to tank.
(2) The fuel supply (to filter) tube, return tube (to
pump module) and fuel supply (to chassis fuel line)
are permanently attached the fuel filter. The ends of
the fuel supply and return tubes have different size
quick-connect fittings.
(3) Apply a light coating of clean 30 weight engine
oil to the fuel filter nipples. Install fuel tubes. Refer
to Fuel Tubes and Quick-Connect Fittings in this sec-
tion.
FUEL PUMP MODULE
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.
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from battery.
(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) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(7) Clean area around fuel tank module and tank
to keep dirt and foreign material out of tank.
(8) Disconnect fuel lines from fuel pump module by
depressing quick connect retainers with thumb and
fore finger (Fig. 14).
(9) Slide fuel pump module electrical connector
lock to unlock.
(10) Push down on connector retainer (Fig. 15) and
pull connector off module.
Fig. 13 Fuel Filter
Fig. 14 Fuel Line Retainers and Pump Connector
Lock
Fig. 15 Pump Module Connector Retainer and Lock
NSFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)

(3) Fold tangs on regulator retainer over tabs on
housing.
FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 20).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on thereservoir body lock over the locking tangs on the
strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from theBOTTOMof
the fuel pump module electrical connector (Fig. 21).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pull off blue locking wedge (Fig. 22).
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 23).
Fig. 19 Fuel Pressure Regulator O-rings
Fig. 20 Inlet Strainer Removal
Fig. 21 Fuel Pump/Level Sensor Electrical
Connector
Fig. 22 Wire Terminal Locking Wedge
NSFUEL SYSTEM 14 - 15
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) 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)