1996 CHRYSLER VOYAGER fuel pump

terminals. Verify the connectors are fully inserted
into the socket of the PCM (Fig. 74). Ensure that
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
inserted into the PDC (Fig. 74). A label affixed to the
underside of the PDC cover identifies the relays and
fuses in the PDC.
(25) Check Battery Cable Connections.
(26) Check hose and wiring connections at fuel
pump module. Check that wiring connector is making
contact with terminals on pump.
VISUAL INSPECTIONÐ3.3/3.8L ENGINES
A visual inspection for loose, disconnected, or mis-
routed wires and hoses should be made before
attempting to diagnose or service the fuel injection
system. A visual check helps save unnecessary test
and diagnostic time. A thorough visual inspection will
include the following checks:
(1) Check ignition cable routing from the coil pack
to the spark plugs. Verify the cable are routed in the
correct order and are fully seated to the coil and
spark plug.(2) Check direct ignition system (DIS) coil electri-
cal connection for damage and a complete connection
to the coil pack (Fig. 75).
(3) Verify the camshaft position sensor electrical
connector is connected to the harness and not dam-
aged (Fig. 76).
(4) Ensure the engine temperature sensor electri-
cal connector is connected to the sensor and not dam-
aged (Fig. 77).
(5) Verify the quick connect fuel fitting is fully
inserted on the fuel supply tube.
(6) Check the oil pressure sending unit electrical
connection (Fig. 78).
Fig. 74 Powertrain Control Module (PCM)
Fig. 75 Ignition Coil Pack Electrical Connection
Fig. 76 Camshaft Position Sensor
NSFUEL SYSTEM 14 - 55
DIAGNOSIS AND TESTING (Continued)

inserted into the PDC (Fig. 90). A label affixed to the
underside of the PDC cover identifies the relays and
fuses in the PDC.
(25) Inspect battery cable connections for corro-
sion.
(26) Check the power brake booster hose connec-
tion (without anti-lock brake systems) (Fig. 91).
(27) Inspect the speed control vacuum connection
(Fig. 92).(28) Inspect hose and wiring connections at fuel
pump module. Check that wiring connector is making
contact with terminals on pump.
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The terminals on the
bottom of each relay are numbered (Fig. 93) or (Fig.
94).
OPERATION
²Terminal number 30 is connected to battery volt-
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times.
Fig. 90 Power Distribution Center (PDC)
Fig. 91 Power Brake Booster Hose
Fig. 92 Speed Control Vacuum
Fig. 93 ASD and Fuel Pump Relay Terminals
NSFUEL SYSTEM 14 - 59
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)

REMOVAL AND INSTALLATION
THROTTLE BODY
REMOVAL
(1) Disconnect negative cable from battery cable.
(2) Remove air inlet to throttle body hose clamp.
(3) Remove 2 screws and air inlet resonator (Fig.
104).
(4) Remove throttle and the speed control (if
equipped) cables from lever and bracket (Fig. 105).
(5) Disconnect electrical connectors from the idle
air control motor and throttle position sensor (TPS)
(Fig. 106) or (Fig. 107) or (Fig. 108).(6) Disconnect vacuum hoses from throttle body.
(7) Remove throttle body to intake manifold
attaching nuts.
(8) Remove throttle body and gasket.
INSTALLATION
(1) Reverse procedure for installation. Tighten
throttle body mounting nuts to 25 N´m (225 in. lbs.)
torque.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
AUTOMATIC SHUTDOWN (ASD) RELAY
The Automatic Shutdown relay (ASD) relay is
located in the PCD. The inside top of the PDC cover
has a label showing relay and fuse location.
Fig. 104 Air Inlet Resonator
Fig. 105 Throttle Cable Attachment to Throttle Body
Attachment
Fig. 106 Throttle Body Electrical and Vacuum
ConnectionsÐ2.4L
Fig. 107 Throttle Body Electrical and Vacuum
ConnectionsÐ3.0L
14 - 64 FUEL SYSTEMNS

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

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

FUEL TANK MODULE
An electric fuel pump is not attached to the fuel
tank module for diesel powered engines. Fuel is sup-
plied by the fuel injection pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 2). The fuel tank module contains the
following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Electric fuel gauge sending unit
²Fuel supply line connection
²Fuel return line connection
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit is attached to the side
of the fuel pump module. The sending unit consists of
a float, an arm, and a variable resistor (track). The
track is used to send an electrical signal used for fuel
gauge operation.
As the fuel level increases, the float and arm move
up. This decreases the sending unit resistance, caus-
ing the fuel gauge on the instrument panel to read
full. As the fuel level decreases, the float and arm
move down. This increases the sending unit resis-
tance, causing the fuel gauge on the instrument
panel to read empty.
FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator assembly is located
in the engine compartment near the strut tower (Fig.
3).
The combination fuel filter/water separator pro-
tects the fuel injection pump by helping to remove
water and contaminants from the fuel. Moisture col-
lects at the bottom of the filter/separator in a plastic
bowl.
The fuel filter/water separator assembly contains
the fuel filter, fuel heater element, and fuel drain
valve.
For information on the fuel heater, refer to Fuel
Heater in this group.
Refer to the maintenance schedules in Group 0 in
this manual for the recommended fuel filter replace-
ment intervals.
Fig. 1 Typical Fuel Pressure Test at Injector
Fig. 2 Fuel Tank
Fig. 3 Fuel Filter/Water Separator Location
14 - 4 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DESCRIPTION AND OPERATION (Continued)

For periodic draining of water from the bowl, refer
to Fuel Filter/Water Separator Removal/Installation
in this group.
FUEL SHUTDOWN SOLENOID
The fuel shutdown solenoid is controlled and
operated by the PCM.
The fuel shutdown (shut-off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
pressure fuel injection pump. The solenoid is
mounted to the rear of the injection pump (Fig. 4).
The solenoid controls starting and stopping of the
engine regardless of the position of the accelerator
pedal. When the ignition (key) switch is OFF, the
solenoid is shut off and fuel flow is not allowed to the
fuel injection pump. When the key is placed in the
ON or START positions, fuel supply is allowed at the
injection pump.
FUEL INJECTION PUMP
The fuel injection pump is a mechanical distribu-
tor±type, Bosch VP36 series (Fig. 5). A gear on the
end of the injection pump shaft meshes with the
drive gear at the front of engine. The pump is
mechanically timed, relative to the position of the
cam and crankshaft. The PCM can make adjust-
ments to the timing of the injection pump.
The injection pump contains the fuel shutdown
solenoid, fuel temperature sensor, control sleeve sen-
sor, fuel quantity actuator and the fuel timing sole-
noid (Fig. 5).In the electronically controlled injection pump, the
pump plunger works the same as the pump plunger
in a mechanically controlled injection pump, but the
amount of fuel and the time the fuel is injected is
controlled by the vehicle's PCM, instead of by a
mechanical governor assembly. A solenoid controlled
by the PCM is used in place of the mechanical gov-
ernor assembly, and it moves a control sleeve inside
the pump that regulates the amount of fuel being
injected. There is no mechanical connection between
the accelerator pedal and the electronically controlled
injection pump. Instead, a sensor connected to the
accelerator pedal sends a signal to the PCM that rep-
resents the actual position of the accelerator pedal.
The PCM uses this input, along with input from
other sensors to move the control sleeve to deliver
the appropriate amount of fuel. This system is known
as ªDrive-By-Wireº
The actual time that the fuel is delivered is very
important to the diesel combustion process. The PCM
monitors outputs from the engine speed sensor (fly-
wheel position in degrees), and the fuel injector sen-
sor (mechanical movement within the #1 cylinder
fuel injector). Outputs from the Accelerator Pedal
Position sensor, engine speed sensor (engine rpm)
and engine coolant temperature sensor are also used.
The PCM will then compare its set values to these
outputs to electrically adjust the amount of fuel tim-
ing (amount of advance) within the injection pump.
This is referred to as ªClosed Loopº operation. The
PCM monitors fuel timing by comparing its set value
to when the injector #1 opens. If the value is greater
than a preset value a fault will be set.
Fig. 4 Fuel Shutdown Solenoid and Overflow Valve
Location
Fig. 5 Fuel Injection Pump
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 5
DESCRIPTION AND OPERATION (Continued)