oil temperature CHRYSLER VOYAGER 1996 Workshop 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

12
- -
2
1V20 18RD CAV FUNCTION CIRCUIT
REAR WASHER MOTOR CONTROL BLACK
WIPER DE-ICER-C1ELECTRIC
ELECTRIC
WIPER DE-ICER-C2
BLACK
WIPER DE-ICE SWITCHED GROUND CIRCUIT FUNCTION
CAV
C66 18BK/WT
1
2--
2 1
SENSOR GROUND K4 20BK/LB
2
1K2 20TN/BK CAV FUNCTION CIRCUIT
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL G58 20BK/YL
3ENGINE COOLANT
TEMPERATURE SENSOR
(DIESEL)
1 2
3
BLACK
(GAS) TEMPERATURE SENSORENGINE COOLANT
12BLACK
K2 18TN/BK K4 18BK/LB
2 1 CAV ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND CIRCUIT
FUNCTION
PRESSURE SWITCHENGINE OIL
BLACK (2.0L)
1GREEN
2
G6 16GY
2 1 CAV ENGINE OIL PRESSURE SWITCH SENSE
- CIRCUIT
- FUNCTION
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29
NSGS8029J988W-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

Component/
GroundColor Location Fig.
Camshaft
Position Sensor
3.3L, 3.8LBK RT Side of
Engine9
Center Dome
LampBK At Lamp N/S
CHMSL RD Rear of CHMSL 21
Cigar Lighter BK Rear of Lighter 9
Clockspring C1 YL Rear of
Clockspring11
Clockspring C2 NAT Rear of
Clockspring11
Clutch Interlock
SwitchBK Top of Clutch
Pedal13
Controller
Anti-Lock BrakeBK RT Side of
Engine
CompartmentN/S
Crankcase Vent
HeaterAt Heater N/S
Crankshaft
Position SensorBK Rear of Engine 5, 6, 7,
9
D01 BK On Kick Panel 18
D02 BK On Kick Panel 18
Data Link
ConnectorBK LT of Steering
Column12
Downstream
Heated Oxygen
SensorBK Front Center of
Floor Pan16
Driver Airbag YL Rear of Airbag 11
E36 BK LT Frame Rail 2
E40 BK At Radiator Fan
ModuleN/S
E43 LT/GY LT Frame Rail 2
E69 BK LT Side of
Intake6, 7
E78 BK Near Throttle
Body9
EC1 Above RT
Vanity Mirror17
EGR Solenoid BK LT Rear of
Engine6, 9
Electric Wiper
De-Icer C1BK At Left Base of
Windshield11
Electric Wiper
De-Icer C2BK At Right Base
of Windshield11Component/
GroundColor Location Fig.
Engine Coolant
Temp Sensor
2.4LBK On Cylinder
BlockN/S
Engine Coolant
Temp Sensor
2.5BK On Cylinder
Head8
Engine Coolant
Temp Sensor
3.3L, 3.8LBK On Cylinder
BlockN/S
Engine Oil
Pressure SwitchGN On Cylinder
Block5, 6, 7,
8, 9
Engine Starter
MotorRear of Starter 5, 6, 7,
8, 9
EVAP/Purge
SolenoidBK RT Motor
Mount3
Evaporator
Temperature
SensorBK RT Side of
HVACN/S
F02 BK Near Throttle
Body9
F09 BK LT Side of
Intake6, 7
Front Blower
MotorBK At Motor 10
Front Blower
Motor Resistor
BlockBK RT Side Cowl 4
Front Cigar
LighterBK Rear of Lighter 9
Front Reading
Lamps/SwitchRD At Lamp 15
Front Washer
MotorBK Bottom of
Reservior4
Fuel Injection
PumpBK Near Pump 8
Fuel Injector #1 BK At Injector N/S
Fuel Injector #2 BK At Injector N/S
Fuel Injector #3 BK At Injector N/S
Fuel Injector #4 BK At Injector N/S
Fuel Injector #5 BK At injector N/S
Fuel Injector #6 BK At Injector N/S
Fuel Injectors
(2.0L)BK At Injectors 5
Fuel Pump
HeaterBK At Heater N/S
Fuel Pump
ModuleLT/GY Side of Fuel
Tank20
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

Component/
GroundColor Location Fig.
Downstream
Heated Oxygen
SensorBK Front Center of
Floor Pan16
Driver Airbag YL Rear of Airbag 11
E36 BK LT Frame Rail 2
E40 BK At Radiator Fan
ModuleN/S
E43 LT/GY LT Frame Rail 2
E69 BK LT Side of
Intake6, 7
E78 BK Near Throttle
Body9
EC1 At Top Center
of Windshield17
EGR Solenoid BK LT Rear of
Engine6, 9
Electric Wiper
De-Icer C1BK At Right Base
of Windshield11
Electric Wiper
De-Icer C2BK At Left Base of
Windshield11
Engine Coolant
Temp Sensor
2.4LBK On Cylinder
BlockN/S
Engine Coolant
Temp Sensor
3.3L, 3.8LBK On Cylinder
BlockN/S
Engine Oil
Pressure SwitchGN On Cylinder
Block5, 6, 7,
8, 9
Engine Starter
MotorRear of Starter 5, 6, 7,
8, 9
EVAP/Purge
SolenoidBK RT Motor
Mount3
Evaporator
Temperature
SensorBK RT Side of
HVACN/S
F02 BK Near Throttle
Body9
F09 BK LT Side of
Intake6, 7
Front Blower
MotorBK At Motor 10
Front Blower
Motor Resistor
BlockBK LT Side of
Engine2
Front Cigar
LighterBK Rear of Lighter 11Component/
GroundColor Location Fig.
Front Reading
Lamps/SwitchBL At Lamp 17
Front Washer
MotorBK Bottom of
Reservior4
Fuel Injector #1 BK At Injector N/S
Fuel Injector #2 BK At Injector N/S
Fuel Injector #3 BK At Injector N/S
Fuel Injector #4 BK At Injector N/S
Fuel Injector #5 BK At Injector N/S
Fuel Injector #6 BK At Injector N/S
Fuel Pump
ModuleGY Side of Fuel
Tank20
G100 LT Frame Rail 3
G101 2.4L Rear of
Cylinder Head6, 7
G101 3.3L, 3.8L Rear of
Cylinder Block9
G102 LT Frame Rail 3
G103 2.4L Rear of
Cylinder Head6, 7
G103 3.3L, 3.8L Rear of
Cylinder Block9
G104 Near T/O for
RT HeadlampN/S
G200 Left of I.P.
Center Stack10
G201 I.P. Center
Support10
G202 I.P. Center
Support10
G204 I.P. Center
Support10
G300 BK LT Kick Panel 13
G301 RT Kick Panel 13, 14
G302 BK LT Quarter
Panel21
G400 BK In Liftgate 23
Generator BK Rear of
Generator5, 6, 7,
8, 9
Glove Box
LampBL Rear of Glove
Box11
Headlamp
Dimmer SwitchBK Part of
Multifunction
Switch11
8W - 90 - 32 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 Engine Oil Container Standard Notations
9 - 6 ENGINENS
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)