engine CHRYSLER VOYAGER 1996 Service Manual

(19) Check the heated oxygen sensor electrical con-
nectors for damage (Fig. 87) and (Fig. 88).(20) Verify the engine ground strap is attached at
the engine and dash panel. Inspect the strap for cor-
rosion or damage.
(21) Inspect the generator wiring connections for
damage.
(22) Check the accessory drive belt tension.
(23) Check the 40-way electrical connectors at the
Powertrain Control Module (PCM) (Fig. 89) for dam-
age or spread terminals. Verify that the connectors
are fully inserted into the PCM sockets. Ensure the
wires are not stretched or pulled out of the connector.
(24) Inspect fuses in the Power Distribution Cen-
ter (PDC). Verify all fuses and relays are fully
Fig. 85 Crankshaft Position Sensor
Fig. 86 MAP Sensor
Fig. 87 Upstream Heated Oxygen Sensor
Fig. 88 Downstream Heated Oxygen Sensor
Fig. 89 Powertrain Control Module (PCM)
Connectors
14 - 58 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

²The PCM grounds the coil side of the relay
through terminal number 85.
²Terminal number 86 supplies voltage to the coil
side of the relay.
²When the PCM de-energizes the ASD and fuel
pump relays, terminal number 87A connects to termi-
nal 30. This is the Off position. In the off position,
voltage is not supplied to the rest of the circuit. Ter-
minal 87A is the center terminal on the relay.
²When the PCM energizes the ASD and fuel
pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
TESTING
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
(6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
power source.Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.(7) Attach the other end of the jumper wire to
relay terminal 86. This activates the relay. The ohm-
meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.
(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the ASD
and fuel pump relay circuits. Refer to group 8W, Wir-
ing Diagrams.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
To perform a complete test of the MAP sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(1) Test the MAP sensor output voltage at the
MAP sensor connector between terminals 2 and 3
(Fig. 95). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts.
The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If
not OK, go to step 3.
(2) Test PCM terminal 36 for the same voltage
described in the previous step to verify wire harness
condition. Repair as required.
(3) Test the MAP sensor ground circuit at sensor
connector terminal 1 and PCM terminal 43. If OK, go
to next step. If not OK, repair as required.
(4) Test MAP sensor supply voltage between sen-
sor connector terminals 2 and 1 with the key ON.
The voltage should be approximately 5 volts (6.5V).
Five volts (6.5V) should also be at terminal 61 of the
Fig. 94 ASD and Fuel Pump Relay Terminals
Fig. 95 MAP Sensor Connector
14 - 60 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
HEATED OXYGEN SENSOR
Use an ohmmeter to test the heating element of
the oxygen sensors. Disconnect the electrical connec-
tor from each oxygen sensor. The white wires in the
sensor connector are the power and ground circuits
for the heater. Connect the ohmmeter test leads to
terminals of the white wires in the heated oxygen
sensor connector. Replace the heated oxygen sensor if
the resistance is not between 4 and 7 ohms.
KNOCK SENSOR
The engine knock sensor is affected by a number of
factors. A few of these are: ignition timing, cylinder
pressure, fuel octane, etc. The knock sensor gener-
ates an AC voltage whose amplitude increases with
the increase of engine knock. The knock sensor can
be tested with a digital voltmeter. The RMS voltage
starts at about 20mVac (at about 700 rpm) and
increases to approximately 600 mVac (5000 rpm). If
the output falls outside of this range a DTC will be
set.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition for Diagnosis and Test-
ing of Camshaft and Crankshaft Sensors.
ENGINE COOLANT TEMPERATURE SENSOR
(1) With the key off, disconnect wire harness con-
nector from coolant temperature sensor (Fig. 96) or
(Fig. 97) or (Fig. 98).
(2) Connect a high input impedance (digital) volt-
ohmmeter to terminals A and B (Fig. 99). The ohm-
meter should read as follows:
(a) ECT STET at normal operating temperature
around 200ÉF should read approximately 700 to
1,000 ohms.
(b) ECT STET at room temperature around 70ÉF
ohmmeter should read approximately 7,000 to
13,000 ohms.
(3) Test the resistance of the wire harness between
the PCM connector terminal 26 and the sensor har-
ness connector. Also check for continuity between
PCM connector terminal 43 and the sensor harness
connector. Refer to Group 8W, Wiring diagrams for
Fig. 96 Engine Coolant Temperature SensorÐ2.4L
Fig. 97 Engine Coolant Temperature SensorÐ3.0L
Fig. 98 Engine Coolant Temperature SensorÐ3.3/
3.8L
NSFUEL SYSTEM 14 - 61
DIAGNOSIS AND TESTING (Continued)

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)

(5) When the sensor is removed, the exhaust man-
ifold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If using original sensor, coat the threads with
Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
(1) Reverse removal procedure to install a new
sensor.
New sensors are packaged with compound on the
threads and no additional compound is required. The
sensor must be tightened to 27 N´m (20 ft. lbs.)
torque.
KNOCK SENSOR
For removal/installation procedures refer to Group
8D- Ignition System, Service Procedures.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove 2 screws and air inlet resonator (Fig.
128).
(2) Loosen 3 clamps holding air cleaner housing
halves together.
(3) Remove left side of air cleaner housing (Fig.
129).
(4) Remove element from air cleaner housing (Fig.
130).
INSTALLATION
(1) Install a new element in housing.
(2) Position left side of housing.
(3) Snap clamps into place.(4) Install hoses and air inlet resonator.
ENGINE COOLANT TEMPERATURE SENSORÐ2.4L
The coolant sensor threads into the top of the ther-
mostat housing (Fig. 131). New sensors have sealant
applied to the threads.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.Fig. 128 Air Inlet Resonator
Fig. 129 Air Cleaner Housing (Left Side)
Fig. 130 Air Cleaner Element
14 - 70 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N´m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
ENGINE COOLANT TEMPERATURE SENSORÐ3.0L
The sensor is installed next to the thermostat
housing (Fig. 114).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N´m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
ENGINE COOLANT TEMPERATURE SENSORÐ3.3/
3.8L
The sensor is installed next to the thermostat
housing (Fig. 132).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N´m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
Fig. 131 Engine Coolant Temperature SensorÐ2.4L
Fig. 132 Engine Coolant Temperature Sensor
NSFUEL SYSTEM 14 - 71
REMOVAL AND INSTALLATION (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

INTRODUCTIONÐ2.0L ENGINE
Refer to the introduction in group 14 for the 2.4/
3.0/3.3/3.8l engines.
FUEL REQUIREMENTSÐ2.5L DIESEL
Refer to the Lubrication and Maintenance section
of this manual for information. Also refer to the
Owner Manual.
FUEL REQUIREMENTSÐ2.0L ENGINE
Your vehicle was designed to meet all emission reg-
ulations and provide excellent fuel economy when
using high quality unleaded gasoline.
Use high quality unleaded gasoline with a mini-
mum research octane rating of 91.
The vehicle will operate on fuels ranging from
unleaded fuel having a minimum research octane of
91 to super unleaded fuel with a minimum research
octane of 98.
GASOLINE/OXYGENATE BLENDS
Refer to Gasoline/Oxygenate blends for the 2.4/3.0/
3.3/3.8l engines in group 14.
Fig. 2 PCM Location
14 - 2 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
GENERAL INFORMATION (Continued)

FUEL DELIVERY SYSTEMÐ2.5L DIESEL ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DRAIN TUBES..................... 7
FUEL FILTER/WATER SEPARATOR.......... 4
FUEL GAUGE SENDING UNIT.............. 4
FUEL HEATER RELAY.................... 8
FUEL HEATER.......................... 8
FUEL INJECTION PUMP.................. 5
FUEL INJECTORS....................... 6
FUEL SHUTDOWN SOLENOID............. 5
FUEL SYSTEM PRESSURE WARNING....... 3
FUEL TANK MODULE.................... 4
FUEL TANK............................ 3
FUEL TUBES/LINES/HOSES AND CLAMPSÐ
LOW-PRESSURE TYPE................. 6
HIGH-PRESSURE FUEL LINES............. 7
INTRODUCTION........................ 3
QUICK-CONNECT FITTINGSÐLOW PRESSURE
TYPE............................... 7
WASTEGATE (TURBOCHARGER)........... 8
DIAGNOSIS AND TESTING
AIR IN FUEL SYSTEM................... 11
FUEL HEATER RELAY TEST.............. 12
FUEL INJECTION PUMP TEST............. 12
FUEL INJECTOR SENSOR TEST........... 12
FUEL INJECTOR TEST.................. 12
FUEL SHUTDOWN SOLENOID TEST........ 13
FUEL SUPPLY RESTRICTIONS............ 13GENERAL INFORMATION................. 9
HIGH-PRESSURE FUEL LINE LEAK TEST.... 14
VISUAL INSPECTION..................... 9
WASTEGATE (TURBOCHARGER).......... 14
SERVICE PROCEDURES
AIR BLEED PROCEDURES............... 14
FUEL INJECTION PUMP TIMING........... 15
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL.................. 16
AIR CLEANER ELEMENT................. 16
FUEL DRAIN TUBES.................... 16
FUEL FILTER/WATER SEPARATOR......... 16
FUEL HEATER RELAY................... 17
FUEL HEATER......................... 17
FUEL INJECTION PUMP................. 19
FUEL INJECTORS...................... 22
FUEL LEVEL SENSOR................... 18
FUEL RESERVOIR MODULE.............. 25
FUEL SHUTDOWN SOLENOID............ 23
FUEL TANK........................... 23
HIGH-PRESSURE LINES................. 26
SPECIFICATIONS
FUEL INJECTOR FIRING SEQUENCE....... 27
FUEL SYSTEM PRESSURE............... 27
FUEL TANK CAPACITY.................. 27
IDLE SPEED.......................... 27
DESCRIPTION AND OPERATION
INTRODUCTION
This Fuel Delivery section will cover components
not controlled by the PCM. For components con-
trolled by the PCM, refer to the Fuel Injection Sys-
temÐ2.5L Diesel Engine section of this group.
The fuel heater relay, fuel heater and fuel gauge
are not operated by the PCM. These components are
controlled by the ignition (key) switch. All other fuel
system electrical components necessary to operate
the engine are controlled or regulated by the PCM.
FUEL SYSTEM PRESSURE WARNING
WARNING: HIGH±PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI).
USE EXTREME CAUTION WHEN INSPECTING FORHIGH±PRESSURE FUEL LEAKS. INSPECT FOR
HIGH±PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD (Fig. 1). HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL TANK
The fuel tank and tank mounting used with the
diesel powered engine is the same as used with gas-
oline powered models, although the fuel tank module
is different.
The fuel tank contains the fuel tank module and
two rollover valves. Two fuel lines are routed to the
fuel tank module. One line is used for fuel supply to
the fuel filter/water separator. The other is used to
return excess fuel back to the fuel tank.
The fuel tank module contains the fuel gauge elec-
trical sending unit.An electrical fuel pump is not
used with the diesel engine.
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 3