engine oil CHRYSLER VOYAGER 1996 Manual Online

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.
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 Rear of Right
Headlamp4
G200 Right of I.P.
Center Stack10
G201 I.P. Center
Support10
G202 I.P. Center
Support10
G204 I.P. Center
Support10
G300 LT Kick Panel 13
G301 RT Kick Panel 14
G302 LT Quarter
Panel21
G400 In Liftgate 23
Generator BK Rear of
Generator5, 6, 7,
8, 9
Glove Box
LampBL Rear of Glove
Box11
Glow #1 BK At Glow Plug 8
Glow #2 BK At Glow Plug 8
Glow #3 BK At Glow Plug 8
Glow #4 BK At Glow Plug 8
Headlamp
Dimmer SwitchBK Part of
Multifunction
Switch11
Headlamp
Switch C1NAT Rear of Switch 11
Headlamp
Switch C2BK Rear of Switch 11
Headlamp
Washer PumpBK At Pump N/S
High Note Horn BK LT Frame Rail 4
Hood Ajar
SwitchNAT LT Fender 2Component/
GroundColor Location Fig.
Horn Switch Rear of Driver
Airbag11
Idle Air Control
MotorBK On Throttle
Body5, 6, 7,
8, 9
Ignition Coil
Pack 2.0LBK Top of Valve
Cover5
Ignition Coil
Pack 2.4LBK Top of Valve
Cover6, 7
Ignition Coil
Pack 3.3L, 3.8LBK RT Side of
Engine9
Ignition Switch
C1GY Rear of Switch 11
Ignition Switch
C2GN Rear of Switch 11
Ignition Switch
C3BK Rear of Switch 11
Instrument
ClusterRD Rear of Cluster 11
Intake Air Temp
SensorGY On Intake 6, 7
J01D BK RT Side of
HVAC15
J02A BK Top of Liftgate 23
JO3A BK Top of Liftgate 23
Junction Block
C1GY On Junction
Block13
Junction Block
C2GY On Junction
Block13
Junction Block
C3GY On Junction
Block12
Junction Block
C4GY On Junction
Block12
Key-In Halo
LampWT Rear of Lamp 11
Knock Sensor
2.0LGY Front of
Cylinder Block5
Knock Sensor
2.4LGY Front of
Cylinder Block6, 7
Knock Sensor
3.3L, 3.8LGY Front of
Cylinder BlockN/S
L15 BK Top of Liftgate 23
L16 BK Top of Liftgate 23
Left Flasher
RelayBK LT Rear
Quarter PanelN/S
Left Door Ajar
SwitchBK LT B-PIllar 14
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
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)

Component/
GroundColor Location Fig.
Headlamp
Switch C1NAT Rear of Switch 11
Headlamp
Switch C2BK Rear of Switch 11
Headlamp
Washer MotorBottom of
ReserviorN/S
High Note Horn BK LT Frame Rail 4
Hood Ajar
SwitchNAT LT Fender 2
Horn Switch Rear of Driver
Airbag11
Idle Air Control
MotorBK On Throttle
Body5, 6, 7,
8, 9
Ignition Coil
Pack 2.4LBK Top of Valve
Cover6, 7
Ignition Coil
Pack 3.3L, 3.8LBK RT Side of
Engine9
Ignition Switch
C1GY Rear of Switch 11
Ignition Switch
C2GN Rear of Switch 11
Ignition Switch
C3BK Rear of Switch 11
Instrument
ClusterRD Rear of Cluster 11
Intake Air Temp
SensorGY On Intake 6, 7
J01D BK RT Side of
HVAC15
J02A BK Top of Liftgate 23
JO3A BK Top of Liftgate 23
Junction Block
C1GY On Junction
Block12, 13
Junction Block
C2GY On Junction
Block12, 13
Junction Block
C3GY On Junction
Block12
Junction Block
C4GY On Junction
Block12
Key-In Halo
LampWT Rear of Lamp 11
Knock Sensor
2.4LGY Front of
Cylinder Block6, 7
Knock Sensor
3.3L, 3.8LGY Front of
Cylinder BlockN/S
L15 BK Top of Liftgate 23Component/
GroundColor Location Fig.
L16 BK Top of Liftgate 23
Left
Combination
RelayBK LT Rear
Quarter PanelN/S
Left Door Ajar
SwitchBK LT B-PIllar 12
Left Door
Arm/Disarm
SwitchBK At Switch 19
Left Door
Courtesy LampBK At Lamp 19
Left Door
SpeakerBK At Speaker 19
Left Fog Lamp GY At Lamp 4
Left Front Door
Lock MotorBK At Motor 19
Left Front Panel
SpeakerBK At Speaker 11
Left Front
Park/Turn
Signal LampBK At Lamp 4
Left Front
Wheel Speed
SensorBK LT Fender Side
Shield2
Left Front
Window MotorRD At Motor 19
Left Headlamp BK At Lamp 2
Left Headlamp
Leveling MotorBK At Motor N/S
Left Liftgate
Flood LampBK At Lamp 23
Left Mid
Reading LampGY At Lamp 17
Left Power Door
Lock SwitchBK At Switch 19
Left Power
Mirror C1RD At Mirror 11
Left Power
Mirror C2BL At Mirror 11
Left Power
Window SwitchOR At Switch 19
Left Rear Lamp
AssemblyBK At Lamp 21
Left Rear Door
Ajar SwitchBK LT C-Pillar 21
Left Rear Pillar
SpeakerBK At Speaker 21
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 33
DESCRIPTION AND OPERATION (Continued)

8W-95 SPLICE LOCATIONS
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1SPLICE LOCATION INDEX.................. 1
SPLICE LOCATIONS (RHD)................ 15
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of the splices in this vehicle. A spliceindex is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for the proper splice number.
SPLICE LOCATION INDEX
Splice Number Location Fig.
BS01 Near Split for Tail Lamps 12
BS02 Near Fuel Tank T/O 12
BS03 Near Instrument Panel T/O 9
BS05 Near Instrument Panel T/O 9
BS05 (2.5L) Near MSA Controller T/O N/S
BS06 Near Instrument Panel T/O 9
BS06 (2.5L) Near MSA Controller T/O N/S
BS08 Near Instrument Panel T/O 9
BS16 Near Right Park Lamp T/O 1
BS17 Near Split for Tail Lamps 12
BS19 Near Horn T/O 1
BS30 (2.5L) Near Generator T/O 5
BS31 Near Left Headlamp Leveling
Motor T/O1
BS31 (2.5L) In BCM T/O 5
BS32 (2.5L) In BCM T/O N/S
BS33 (2.5L) In BCM T/O N/S
BS34 (2.5L) In BCM T/O N/S
BS40 (2.5L) In Engine Harness T/O 5
BS41 (2.5L) In Engine Harness T/O N/S
CS01 Above Right Rear Door 11
CS02 Above Right Rear Door 11
CS03 Right B-Pillar 11
CS04 Right B-Pillar 11
DS01 Near LT Power WDO T/O 10
ES01 In TCM T/O 7
ES01 (2.5L) Near Battery Positive Terminal
T/ON/SSplice Number Location Fig.
ES02 (2.0L) Near Camshaft Position
Sensor T/O3
ES02 (2.4L) Near Fuel Rail T/O 4
ES02 (2.5L) Near Engine Speed Sensor
T/O5
ES02
(3.3L,3.8L)Near Transmission T/O 6
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03
(3.3L,3.8L)Near Body Ground T/O 7
ES05 (2.4L) Near Knock Sensor T/O 4
ES05 (2.5L) In Fuel Injection Pump T/O 5
ES05
(3.3L,3.8L)Near Transmission T/O 6
ES06 (2.5L) Near Needle Movement
Sensor T/O5
ES06
(3.3L,3.8L)Near Transmission T/O N/S
ES07 (2.0L) Near Engine Ground T/O 2
ES07 (2.5L) Near Battery Negative
Terminal T/ON/S
ES07 (2.4L) Near Body Ground T/O 4, 7
ES07
(3.3L,3.8L)Near Battery Negative
Terminal T/O6
ES08
(3.3L,3.8L)Near Transmission T/O 6
ES09 (2.0L) In Battery Positive Terminal
T/O7
ES09 (2.4L) Near Battery Positive Terminal 4
NS/GS8W - 95 SPLICE LOCATIONS 8W - 95 - 1

Splice Number Location Fig.
ES09 (2.5L) In Battery Positive Terminal
T/ON/S
ES09
(3.3L,3.8L)In Battery Positive Terminal
T/O7
ES10 Near Knock Sensor T/O 6
ES10
(3.3L,3.8L)Near Transmission T/O 7
ES11 (2.0L) Near Battery Positive Terminal
T/O7
ES11 (2.4L) Near Battery Negative
Terminal T/O4
ES11 (2.5L) In Generator T/O N/S
ES11
(3.3L,3.8L)Near Battery Negative
Terminal7
ES12 (2.4L) Near Throttle Body T/O 4
ES12 (2.5L) Near Battery Negative
Terminal T/ON/S
ES12
(3.3L,3.8L)Near Battery Positive Terminal
T/O7
ES13 (2.4L) Near Generator T/O 4
ES13
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES14 (2.4L) Near Generator T/O 4,7
ES14
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES17 (2.0L) Near Camshaft Position
Sensor T/O3
ES17 (2.4L) Near Engine Ground T/O 4
ES17
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES18 (2.0L) Near Camshaft Position
Sensor T/O3
ES18 (2.4L) Near Engine Ground T/O 4
ES18
(3.3L,3.8L)Near Engine Ground T/O 7Splice Number Location Fig.
ES21 (2.0L) Near Body Ground T/O N/S
ES21 (2.4L) Near Engine Ground T/O 4
ES21
(3.3L,3.8L)Near A/C Clutch T/O 6
ES23 (2.0L) Near Radiator Fan T/O N/S
ES23 (2.4L) Near Radiator Fan T/O 4
ES23
(3.3L,3.8L)Near Engine ground T/O 7
ES24 (2.4L) Near Transmission T/O 4
ES24
(3.3L,3.8L)Near Transmission T/O 7
ES26 (2.5L) In Battery Positive Terminal
T/ON/S
ES28 (2.5L) In Battery Positive Terminal
T/ON/S
ES29 (2.5L) Near Glow Plug Relay T/O N/S
ES30 (2.5L) Near Fuel Heater T/O 5
ES31 (2.5L) Near Fuel Heater T/O 5
ES37 (2.5L) Near Oil Pressure Switch T/O 5
ES40 (2.5L) Near Fuel Injection Pump T/O 5
ES99 (2.0L) Near Knock Sensor T/O 2
FS01 (2.4L) Near ECT Sensor T/O N/S
FS01
(3.3L,3.8L)Near Injector #5 T/O N/S
FS02 (2.4L) Near Inj #2 T/O N/S
FS02
(3.3L,3.8L)Between Inj's 4 and 6 N/S
FS03 (2.4L) Between Inj #2 and #3 N/S
PS01 Near Steering Column T/O 8
PS02 Near Steering Column T/O 8
RFS01 Near Radiator Fan #2 N/S
RFS02 Near Radiator Fan #1 N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

SPLICE LOCATIONS (RHD)
Splice Number Location Fig.
BS01 Near Split for Tail Lamps 11
BS02 Near Fuel Tank T/O 11
BS03 Near I/P Bulkhead
Connector T/O8
BS05 Near Left Door T/O N/S
BS06 Near Left Door T/O N/S
BS08 Near Clutch Interlock switch
T/O8
BS16 Near RT Park Lamp T/O 1
BS17 Near Split for Tail Lamps 11
BS31 Near Left Headlamp
Leveling Motor T/O1
CS01 Above Right Rear Door 10
CS02 Above Right Rear Door 10
CS03 Right B-Pillar 10
CS04 Right B-Pillar 10
DS01 Near LT Power WDO T/O 9
ES01 In TCM T/O 6
ES02 (2.0L) Near Camshaft Position
Sensor T/O3
ES02 (2.4L) In Throttle Body T/O 4
ES02 (3.3L, 3.8L) Near Transmission T/O 5
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03 (3.3L, 3.8L) Near Body Ground T/O 6
ES05 (2.4L) Near Knock Sensor T/O 4
ES05 (3.3L, 3.8L) Near Transmission T/O 5
ES06 Near Transmission T/O N/S
ES07 (2.0L) Near Engine Ground T/O 2
ES07 (2.4L) Near Body Ground T/O 4
ES07 (3.3L, 3.8L) Near Battery Negative
Terminal T/O6
ES08 (2.4L) Near Transmission T/O 4,6
ES09 (2.0L) Near Battery Positive
TerminalN/S
ES09 (2.4L) Near Battery Positive
Terminal4
ES09 (3.3L, 3.8L) Near Battery Positive
Terminal6
ES10 (2.4L) Near Knock Sensor T/O 6
ES10 (3.3L, 3.8L) Near Transmission T/O 5
ES11 (2.0L) Near Battery Positive
TerminalN/SSplice Number Location Fig.
ES11 (2.4L) Near Battery Negative
Terminal T/O4
ES11 (3.3L, 3.8L) Near Battery Negative
Terminal5,6
ES12 (2.0L) Near Engine Ground T/O 2
ES12 (2.4L) Near Throttle Body T/O 4
ES12 (3.3L, 3.8L) Near Battery Positive
Terminal T/O6
ES13 (2.4L) Near Generator T/O 4
ES13 (3.3L, 3.8L) Near Battery Negative
Terminal4
ES14 (2.4L) Near Generator Field T/O 4
ES14 (3.3L, 3.8L) Near Battery Negative
Terminal4
ES17 (2.0L) Near Camshaft Position
Sensor T/O3
ES17 (2.4L) Near Engine Ground T/O 4
ES17 (3.3L, 3,8L) Near Battery Negative
Terminal4
ES18 (2.0L) Near Camshaft Position
Sensor T/O3
ES18 (2.4L) Near Engine Ground T/O 4
ES18 (3.3L, 3.8L) Near Engine Ground T/O 6
ES21 (2.0L) Near Body Ground T/O N/S
ES21 (2.4L) Near Back Up Lamp Switch
T/O4
ES21 (3.3L, 3.8L) Near A/C Clutch T/O 5
ES23 (2.0L) Near Radiator Fan T/O N/S
ES23 (2.4L) Near Radiator Fan T/O 4
ES23 (3.3L, 3.8L) Near Body Ground T/O 6
ES24 Near Transmission T/O 4,6
ES24 (3.3L, 3.8L) Near Transmission T/O 5
ES99 (2.0L) Near Knock Sensor T/O 2
FS01 (2.4L) Near ECT Sensor T/O N/S
FS01 (3.3L, 3.8L) Near Injector #5 T/O N/S
FS02 (2.4L) Near Inj #2 T/O N/S
FS02 (3.3L, 3.8L) Between Inj's 4 and 6 N/S
FS03 (2.4L) Between Inj #2 and #3 N/S
PS01 Near Steering Column T/O 7
PS02 Near Steering Column T/O 7
RFS01 Near Radiator Fan #2 N/S
RFS02 Near Radiator Fan #1 N/S
NS/GS8W - 95 SPLICE LOCATIONS 8W - 95 - 15
DESCRIPTION AND OPERATION (Continued)

ENGINE
CONTENTS
page page
2.4L ENGINE............................ 14
3.0L ENGINE............................ 61
3.3/3.8L ENGINE........................ 93ENGINE DIAGNOSIS....................... 7
STANDARD SERVICE PROCEDURES.......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION
CRANKSHAFT SPROCKET BOLT ACCESS
PLUG................................ 2
ENGINE CORE PLUGS.................... 2
ENGINE OIL SERVICE..................... 5
ENGINE OIL............................. 5
ENGINE PERFORMANCE.................. 2FORM-IN-PLACE GASKETS................. 1
HONING CYLINDER BORES................ 3
HYDROSTATIC LOCKED ENGINE............ 5
MEASURING MAIN BEARING AND
CONNECTING ROD BEARING
CLEARANCES......................... 3
REPAIR OF DAMAGED OR WORN THREADS . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets.Do not use
form-in-place gasket material unless specified.
Bead size, continuity, and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over, a continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine.MopartSilicone Rubber Adhe-
sive Sealant andMopartGasket Maker, (anaerobic)
each have different properties and cannot be used
interchangeably.
CAUTION: Silicone sealer and anaerobic sealers
each will inhibit the cure of the other and care
should be taken to keep usages separated as much
as possible.
MOPARTSILICONE RUBBER ADHESIVE
SEALANT
MopartSilicone Rubber Adhesive Sealant or
equivalent, normally black in color, is available in
three ounce tubes. Moisture in the air causes the
MopartSilicone Rubber Adhesive Sealant material
to cure. This material is normally used on flexible
metal flanges. It has a shelf life of one year and will
not properly cure if over age. Always inspect the
package for the expiration date before use.
MOPARTGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material normally red in color. The material cures in
the absence of air when squeezed between two metal-
lic surfaces. It will not cure if left in the uncovered
tube. It is normally red in color. The anaerobic mate-
rial is for use between two machined surfaces. Do not
use on flexible metal flanges.
MOPARTTORQUE CURE GASKET MAKER
MopartTorque Cure Gasket Maker is a unique
anaerobic type gasket material to be usedONLY
between the bedplate and engine block. The material
cures in the absence of air when torqued between
two metallic surfaces. It will not cure if left in the
uncovered tube. This anaerobic material is specially
NSENGINE 9 - 1

made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
TheMopartSilicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3 mm (0.120 in.) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop
is placed in the center of the gasket contact area.
Uncured sealant may be removed with a shop towels.
Components should be torqued in place while the
sealant is still wet to the touch (within 10 minutes).
The usage of a locating dowel is recommended during
assembly to prevent smearing of material off loca-
tion.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmlywith pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at
least 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINENS
GENERAL INFORMATION (Continued)