servo CHRYSLER VOYAGER 1996 Workshop Manual

8W-33 VEHICLE SPEED CONTROL
Component Page
Accelerator Pedal Position Sensor.........8W-33-5
Body Control Module...................8W-33-4
BS01...............................8W-33-5
BS30...............................8W-33-4
BS32...............................8W-33-5
Clockspring........................8W-33-2, 4
Clutch Switch........................8W-33-5
Dump Solenoid.......................8W-33-3
ES18...............................8W-33-3
Fuel Pump Module....................8W-33-5
Fuse 13 (PDC)........................8W-33-5
G101...............................8W-33-3
G200.............................8W-33-2, 4Component Page
G300.............................8W-33-3, 5
Junction Block........................8W-33-3
Left Headlamp Leveling Motor...........8W-33-5
Left Speed Control Switch.............8W-33-2, 4
Power Distribution Center..............8W-33-5
Powertrain Control Module........8W-33-2, 3, 4, 5
Right Speed Control Switch............8W-33-2, 4
Stop Lamp Switch...................8W-33-3, 5
Transmission Control Module............8W-33-2
Vacuum Solenoid......................8W-33-3
Vehicle Speed Control Servo.............8W-33-3
Vehicle Speed Sensor.................8W-33-2, 4
Vent Solenoid........................8W-33-3
NS/GS8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1

56C280C2
CONTROL SOLENOIDVACUUM CONTROLSPEED SPEED
CONTROL
VENT
SOLENOID
CONTROL
41
2
V36
18
TN/RDV35
18
LG/RD
SERVO CONTROL
SPEED
VEHICLE
Z1
18
BK
Z1
10
BK
ES18
G101
STOP
LAMP
SWITCH
4
SPEED
CONTROL
ON/OFF
SWITCH
POWERTRAIN
CONTROL
MODULE
C1
5
DB/RD20 V30
3
VACUUM
SOLENOID
SOLENOID DUMP SOLENOID VENT
3
62C2
SENSE SWITCHLAMPSTOP
YL/RD18 V32
YL/RD20 V32
E43
B70
3
6B70
E43
V30
18
DB/RD
7K29
18
WT/PK
1
Z1
20
BK
2
WT/PK20 K29
G300
6
RHD LHD
JUNCTION
BLOCK
TO5
6SENSE
(8W-15-2)
(8W-15-2)(8W-30-13)
(8W-30-19)
(8W-30-27)
(8W-15-7)(8W-12-19)
NS/GS8W-33 VEHICLE SPEED CONTROL
GAS8W - 33 - 3
GS003303J988W-3

Component Page
Seat Belt Switch.....................8W-80-83
Sentry Key Immobilizer Module.........8W-80-83
Speed Control Dimming Module.........8W-80-83
Stop Lamp Switch....................8W-80-83
Throttle Position Sensor (2.0L)..........8W-80-84
Throttle Position Sensor (Except 2.0L). . . .8W-80-84
Traction Control Switch................8W-80-84
Trailer Tow Connector.................8W-80-84
Transmission Control Module...........8W-80-85Component Page
Transmission Control Solenoids..........8W-80-86
Transmission Range Sensor.............8W-80-86
Turbine Speed Sensor.................8W-80-87
Turbo Boost Pressure Sensor............8W-80-87
Upstream Heated Oxygen Sensor........8W-80-87
Vehicle Speed Control Servo............8W-80-87
Vehicle Speed Sensor..................8W-80-88
Wiper Module (Built-Up-Export).........8W-80-88
Wiper Module (Except Built-Up-Export) . . .8W-80-88
8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTSNS/GS

CONTROL SERVOVEHICLE SPEED
41BLACK
Z1 18BK V30 18DB/RD V35 18LG/RD
V36 18TN/RD
4 3
2 1 CAV GROUND STOP LAMP SWITCH OUTPUT SPEED CONTROL VENT SOLENOID CONTROL
SPEED CONTROL VACUM SOLENOID CONTROL CIRCUIT
FUNCTION
OXYGEN SENSOR UPSTREAM HEATED
4 32
K41 18BK/DG K4 18BK/LB A142 18DG/OR
Z1 18BK
4 3
2 1 CAV UPSTREAM HEATED OXYGEN SENSOR SIGNAL SENSOR GROUND ASD RELAY OUTPUT
GROUND CIRCUIT
FUNCTION GRAY
1BOOST PRESSURE SIGNAL K1 18DG/RD
4
4 1
TURBO BOOST
PRESSURE SENSOR
(DIESEL)
K9 18LB
3K21 18BK/RD INTAKE AIR TEMPERATURE SIGNALSENSOR GROUND K4 18BK/LB
21
CAV FUNCTION CIRCUIT FUNCTION
CIRCUIT
SPEED SENSOR GROUND
INPUT SPEED SENSOR SIGNALCAV
1
2T13 18DB/BK
T52 18RD/BK
GRAY
1 2
TURBINE
SPEED SENSOR
5 VOLT SUPPLY
NS/GS8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87
NSGS8087J988W-3

Component/
GroundColor Location Fig.
Transmission
Control
SolenoidsBK Front of
Transmission7, 9
Turbine Speed
SensorGY Front of
Transmission7, 9
Turn Signal/
Hazard SwitchBK Part of
Multifunction
Switch11
Upstream
Heated Oxygen
SensorGY Rear of Engine 5, 6, 7,
8, 9Component/
GroundColor Location Fig.
Vehicle Speed
Control ServoBK LT Rear of
Engine
Compartment5, 6, 7,
8, 9
Vehicle Speed
SensorBK Rear of
Transmission5, 6, 8
Windshield
Wiper SwitchBK Part of
Multifunction
Switch11
Wiper Module BK LT Side of
Engine2
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7
DESCRIPTION AND OPERATION (Continued)

Component/
GroundColor Location Fig.
Right Rear
Sliding Door
ContactBK RT B-Pillar 14
Right Rear
Sliding Door
Lock MotorBK At Motor N/S
Right Rear
SpeakerBK At Speaker 22
Right Rear Vent
MotorNAT At Motor 22
Right Rear
Wheel Speed
SensorGY Center Rear of
Floor Pan16
Right Repeater
LampGY At Lamp N/S
Right Speed
Control SwitchRight Side of
Steering Wheel
Pad11
Right Stop/Turn
Signal RelayBK LT Quarter
PanelN/S
Right Visor/
Vanity LampBK At Lamp 17
S02 BK Under Seat N/S
Seat Belt Switch BK RT B-Pillar N/S
Sentry Key
Immobilizer
ModuleBK Near Steering
Column at
Module11
Stop Lamp
SwitchGY Top of Brake
Pedal12
T05 BK LT Quarter
PanelN/S
T08 BK RT Quarter
PanelN/SComponent/
GroundColor Location Fig.
Throttle Position
SensorNAT On Throttle
Body5, 6, 7,
8, 9
Trailer Tow
ConnectorBK LT Quarter
PanelN/S
Transmission
Control ModuleBK RT Fender Side
Shield3
Transmission
Range SensorBK Top of
Transmission7. 9
Transmission
Control
SolenoidsBK Front of
Transmission7, 9
Turbine Speed
SensorGY Front of
Transmission7, 9
Turn Signal/
Hazard SwitchBK Part of
Multifunction
Switch11
Upstream
Heated Oxygen
SensorGY Rear of Engine 5, 6, 7,
8, 9
Vehicle Speed
Control ServoBK LT Rear of
Engine
Compartment5, 6, 7,
8, 9
Vehicle Speed
SensorBK Rear of
Transmission5, 6, 8
Windshield
Wiper SwitchBK Part of
Multifunction
Switch11
Wiper Module BK LT Side of
Engine2
8W - 90 - 36 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

2.4L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 15
ENGINE IDENTIFICATION................. 14
ENGINE LUBRICATION SYSTEM............ 14
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 16
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 20
FITTING CONNECTING ROD BEARINGS..... 18
FITTING MAIN BEARINGS................. 19
FITTING PISTON RINGS.................. 16
FITTING PISTONS....................... 16
VALVE SERVICE RECONDITION............ 21
REMOVAL AND INSTALLATION
BALANCE SHAFTS CARRIER ASSEMBLY..... 30
CAMSHAFT FOLLOWER.................. 30
CAMSHAFT OIL SEALÐFRONT............. 41
CAMSHAFT............................ 28
CRANKSHAFT OIL SEALÐFRONT........... 42
CRANKSHAFT OIL SEALÐREAR............ 43
CRANKSHAFT.......................... 46
CYLINDER HEAD COVER................. 28
CYLINDER HEAD........................ 34
ENGINE ASSEMBLY...................... 26
ENGINE MOUNTÐFRONT................. 23
ENGINE MOUNTÐLEFT.................. 24
ENGINE MOUNTÐREAR.................. 25
ENGINE MOUNTÐRIGHT................. 24HYDRAULIC LASH ADJUSTER.............. 33
OILFILTER ............................ 47
OILPAN ............................... 45
OIL PUMP............................. 47
PISTON AND CONNECTING ROD........... 49
STRUCTURAL COLLAR................... 25
TIMING BELT COVER.................... 37
TIMING BELT TENSIONER ASSEMBLY....... 40
TIMING BELT........................... 37
VALVE SPRINGS AND
VALVE SEALS IN VEHICLE............... 33
VALVES AND VALVE SPRINGS............. 35
VIBRATION DAMPER.................... 36
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................. 50
CLEANING AND INSPECTION
OIL PUMP............................. 52
CRANKSHAFT.......................... 52
CYLINDER BLOCK....................... 54
CYLINDER HEAD........................ 51
VALVE AND VALVE SPRING................ 51
ADJUSTMENTS
ENGINE MOUNTS....................... 54
SPECIFICATIONS
2.4L ENGINE........................... 55
TORQUE CHART 2.4L.................... 57
SPECIAL TOOLS
2.4L ENGINE........................... 58
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
ENGINE LUBRICATION SYSTEM
OIL PAN
A structural die cast aluminum oil pan provides
lower engine protection as well as serving as the
engine oil reservoir. Oil pan is attached to block and
sealed with a gasket. The oil pickup tube has a
strainer and cover.
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow fil-
ter to the main oil gallery running the length of thecylinder block. Oil pickup, pump and check valve pro-
vide oil flow to the main oil gallery.
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylin-
der head bolt to an oil gallery running the length of
the cylinder head. The camshaft journals are par-
tially slotted to allow a predetermined amount of
pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam-
shaft lobes.
9 - 14 2.4L ENGINENS

(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.) (Fig. 22).
Tighten through bolt to 75 N´m (55 ft. lbs.)
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
(1) Raise vehicle on hoist.
(2) Support the transmission with a transmission
jack so it will not rotate.
(3) Remove the insulator through bolt from the
mount and rear suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount.
(5) Reverse the removal procedure for installation.
Refer to (Fig. 23).
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
driveshaft assembly length. See Engine Mount
Adjustments in this section.
Check and reposition right engine mount insulator.
Adjust drive train position, if required, for the follow-
ing conditions:
²Driveshaft distress: See Group 2, Suspension
and Driveshafts.
²Any front end structural damage (after repair).
²Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7, Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
(24) Lower the vehicle.
Fig. 22 Engine MountÐLeft
Fig. 23 Engine MountÐRear
NS3.0L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
drive shaft assembly length.
Check and reposition right engine mount insulator.
See Adjustments in this section. Adjust drive train
position, if required, for the following conditions:
a. Drive shaft distress. See Group 2, Suspension
and Driveshafts.
b. Any front end structural damage (after repair).
c. Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to group 14 fuel system for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7 Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Group
7, Accessory Drive Belts located in Cooling System
for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove right and left inner
splash shields.
(15) Remove crossmember cradle plate (Fig. 27).
(16) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(17)(AWD equipped)Mark orientation and sepa-
rate propeller shaft from power transfer unit. Refer
to Group 3, Differential and Driveline for procedure.
(18) Disconnect exhaust pipe from manifold.
(19) Remove front engine mount and bracket as an
assembly.
Fig. 25 Engine MountingÐLeft
Fig. 26 Engine MountingÐRear
Fig. 27 Crossmember Cradle Plate
9 - 104 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (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)