coolant temperature CHRYSLER VOYAGER 1996 Workshop Manual

M20 20BR G75 18TN G10 18LG/RD
G76 18TN/YL V14 18RD/VT G78 18TN/BK G29 20BK/TN P96 20WT/LG G6 20GY V20 20BK/WT V13 18BR/LG G74 18TN/RD G77 18TN/OR
G4 18DB
P97 20WT/DG
P98 20WT/RD
G70 18BR/TN V7 20DG/WT
80 79 78
77
76 75 74 73 72 71
70
69 68 67
66
65
64
63 62 61 60 59 58 57 56 55 54 53
52 51 50 49 48 47
46
45
44
43
42 41 CAV COURTESY LAMP GROUND DRIVER DOOR AJAR SWITCH SENSE SEAT BELT SWITCH SENSE
RIGHT REAR DOOR AJAR SWITCH SENSE WIPER ON/OFF RELAY CONTROL LIFTGATE AJAR SWITCH SENSE WASHER FLUID SWITCH SENSE PASSENGER DOOR SWITCH MUX ENGINE OIL PRESSURE SWITCH SENSE REAR WASHER MOTOR CONTROL REAR WIPER MOTOR CONTROL PASSENGER DOOR AJAR SWITCH SENSE LEFT REAR DOOR AJAR SWITCH SENSE
FUEL LEVEL SENSOR SIGNAL
DRIVER DOOR SWITCH MUX
LIFTGATE LOCK/UNLOCK MUX
HOOD AJAR SWITCH SENSE WIPER PARK SWITCH SENSE
- -
-
-
-
- - -
-
- - - CIRCUIT
- -
-
-
-
- - -
-
- - - FUNCTION
G7 18WT/OR*
V38 20LB/RD*
G18 20PK/BK*
G58 20BK/YL* ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
G55 20OR/BK* ENGINE DISABLE SIGNALPOWER MIRROR FOLD RELAY P171 20VT/WT
P174 20YL/RD POWER MIRROR UNFOLD RELAY
ENGINE SPEED SENSOR SIGNAL K159 20VT/RD*
BODY
CONTROL
MODULE - C1
NATURAL
80 70 60 50
71 61 51 41 L24 20WT/LG**
L193 20OR/WT**
* DIESEL
** GAS
BUILT-UP-EXPORT
VEHICLE SPEED SENSOR SIGNAL
AUTOMATIC HEADLAMP SIGNAL
SPEED CONTROL LAMP DRIVER
COOLANT LEVEL SWITCH SENSE
LOW BEAM RELAY CONTROL
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15
NSGS8015J988W-3

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

POWER SEAT
CIRCUIT BREAKER
2 1GRAY
2F35 14RD* F35 14RD A3 12PK/BK 1 CAV FUSED B(+) FUSED B(+) FUNCTION CIRCUIT
* MEMORY SEAT
(DIESEL) MODULE CONTROL POWERTRAIN
46 68
23
1
CONTINUED ON NEXT PAGE V37 20RD/LG SPEED CONTROL SWITCH SIGNAL- - - - - - - - SLEEVE POSITION SENSOR K134 20LB/BKA/C COMPRESSOR CLUTCH RELAY CONTROL C13 20DB/ORSPEED CONTROL LAMP DRIVER V38 20LB/RDGROUND Z12 16BK/TNDIESEL POWER RELAY OUTPUT A142 16DG/OR- ENGINE SPEED SENSOR RETURN K3 20BK/VT5 VOLT SUPPLY K7 20OR- - ACCELERATOR PEDAL SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
K22 20OR/DB K2 20TN/BKNEEDLE MOVEMENT SENSOR SIGNAL K67 20BR/BKFUEL QUANTITY ACTUATOR SIGNAL
- -
- - FUEL QUANTITY ACTUATOR SIGNAL K140 18TN/WTGROUND Z12 16BK/TN
ENGINE SPEED SENSOR SIGNAL K159 20VT/RD
FUNCTION
-
-
-
- CIRCUIT
-
-
- ENGINE STARTER MOTOR RELAY CONTROL
LOW SPEED RADIATOR FAN RELAY NO. 2 CONTROL
CONTROL SLEEVE POSITION SENSOR
ENGINE SPEED SENSOR FEED
NEEDLE MOVEMENT SENSOR RETURN
A/C PRESSURE SWITCH SIGNAL
CLUTCH SWITCH SIGNAL
GLOW PLUG LAMP DRIVER
SENSOR GROUND
A/C SWITCH SIGNAL
BOOST PRESSURE SENSOR SIGNALCAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40 K90 20TN
K140 18TN/WT
C24 20DB/PK
K57 20LG/OR
K24 18GY/BK
K68 20LG/YL
C18 20DB
K119 20LG/BK
K29 20WT/PK
G85 20OR/BK
K4 20BK/LB
C103 20DG/LB
K1 20DG/RD
EGR SOLENOID CONTROL K35 20GY/YL
FUSED IGNITION (ST-RUN) F87 18WT/BK
(2.0L/2.4L) PRESSURE SWITCHPOWER STEERING
21
BLACK
Z1 18BK K10 18DB/OR
2 1 CAV GROUND POWER STEERING PRESSURE SWITCH SENSE FUNCTION CIRCUIT
BRAKE SWITCH SENSE
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69
NSGS8069J988W-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)

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)

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect the battery.
(2) Remove the air cleaner assembly and inlet
hose.
(3) Remove both hoses at intercooler and engine.
(4) Disconnect EGR vacuum hose.
(5) Disconnect brake booster vacuum hose.
(6) Disconnect oil pressure switch connector (Fig.
19).
(7) Disconnect Wiring harness bracket at transaxle
shift tower.
(8) Disconnect transaxle wiring at speed sensor,
crank sensor, and backup light switch.
(9) Remove both transmission shift cables at trans-
mission.
(10) Remove negative battery cable at cylinder
block (Fig. 19).
(11) Remove oil separator.
(12) Remove connectors at coolant temperature
sensor and A/C compressor.
(13) Disconnect fuel injection pump wiring connec-
tors (Fig. 19).
(14) Disconnect glow plug connectors.
(15) Disconnect electrical connector at number 1
fuel injector.
(16) Raise vehicle on hoist.
(17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drain the cooling system (refer to Group 7,
Cooling).
(19) Lower vehicle.
(20) Remove Coolant pressure bottle and discon-
nect low coolant level sensor.
(21) Disconnect both heater hoses.
(22) Remove the lower radiator hose.
(23) Remove the upper radiator hose.
(24) Remove fuel line at injector pump and cap.
(25) Remove power steering reservoir and reposi-
tion.
(26) Remove upper radiator crossmember.
(27) Disconnect cooling fan module connector.
Fig. 18 Shift Cables at Rear MountFig. 19 Component Locations
Fig. 20 Right Side Splash Shield
NS/GSENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

70É using angle torque tool. Then rotate the bolts an
additional 70É following tightening sequence.
(10) Then, tighten the 14mm bolts with special
tool VM-1018 in the following manner:
(11) Side bolts (M1-M2): Tighten M1 bolts to 30
N´m, then rotate them 85É (65). Tighten M2 bolts to
30 N´m, then rotate them 85É (65).
(12)2nd Phase:After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(13) Central bolts A-L: Starting from bolt A,
slacken and retorque it immediately to 30 N´m + 65É.
Rotate the bolt an additional 65É. Then proceed in
the same way, bolt by bolt, following alphabetical
order, as indicated.
(14) Side bolts M1-M2:Without slackening,
torque bolts M1 then bolts M2 to 90 N´m (66 ft. lbs.).
(15) Tighten intake nuts to 30 N´m (22 ft. lbs.) and
exhaust manifolds nuts to 30 N´m (22 ft. lbs.) speci-
fied torque after completing Phase 2.
(16) If the engine cylinder head is to be replaced
and the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(17) Tighten oil feed lines for rocker arm assem-
blies and oil pressure switch to 13 N´m (112 in. lbs.).
(18) Install push rods and rocker arm assemblies,
tighten nut to 29.4 N´m (264 in. lbs.).(19) Install fuel injectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) Install valve cover, tighten nuts to 14.7 N´m
(132 in. lbs.).
(21) Connect crankcase breather hose.
(22) Connect the injector sensor wire connector,
and the glow plug connectors.
(23) Install oil feed line, tighten banjo bolts to 12.7
N´m (108 in. lbs), and oil drain line to turbo.
(24) Install water manifold tighten bolts to 12 N´m
(106 in. lbs.).
(25) Install exhaust pipe to turbo elbow, tighten
bolts to 28 N´m (250 in. lbs.).
(26) Install the support strut from block to turbo-
charger exhaust elbow.
(27) Install EGR tube to EGR valve, tighten bolts
to 26 N´m (19 ft. lbs.).
(28) Install intercooler hoses at intake manifold.
(29) Install coolant pressure bottle and hoses.
(30) Install wiper module. Refer to Group 8K,
Windshield Wiper Unit Installation for procedure.
(31) Install intercooler hose at turbocharger tube.
(32) Install fuel injector lines from the pump to
injectors, tighten nuts to 17.6 N´m (156. lbs.).
(33) Connect the upper radiator hose.
(34) Connect negative cable to battery.
(35) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GSENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

(5) Drain cooling system. Refer to Group 7, Cool-
ing System for procedure.
(6) Remove heater, and upper radiator hoses at
intake manifold.
(7) Disconnect coolant temperature sensor (Fig.
14).
(8) Remove the accessory drive belt. Refer to
Accessory Drive belt Removal and Installation in
Group 7, Cooling System for procedure.
(9) Remove fasteners attaching generator bracket
to cylinder head, and block.
(10) Remove intake manifold center support
bracket bolts (Y bracket) (Fig. 15)
(11) Disconnect fuel injector harness.(12) Remove lower intake manifold fasteners (Fig.
16). Remove the manifold from engine.
(13) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
If the following items were removed, install and
torque to:
²Fuel Rail Bolts 22 N´m (200 in. lbs.)
²Engine Outlet Connector Bolts 28 N´m (250 in.
lbs.)
²Coolant Temperature Sensor 7 N´m (60 in. lbs.)
²Intake Air Temperature Sensor 28 N´m (250 in.
lbs.)
(1) Using a new intake gasket, position intake
manifold on the engine and install retaining bolts.
Fig. 13 Fuel Line Quick Disconnect
Fig. 14 Coolant Temperature SensorÐ2.4L
Fig. 15 Intake Manifold Center Support Bracket
Fig. 16 Intake Manifold Fasteners
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)