1996 CHRYSLER VOYAGER belt

(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)

the intake manifold. Refer to Group 11, Exhaust Sys-
tem and Intake Manifold for information.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not leaking. The pump is
located on the front of engine (internal) and is driven
from the crankshaft gear and chain (Fig. 20). Discon-
nect the hose and check for minimum vacuum from
the pump. Refer to Group 5, Brake System for spec-
ifications and procedures.(22) Be sure that the accessory drive belt is not
damaged or slipping.
(23) Verify there is a good connection at the engine
speed sensor. Refer to the Fuel Injection System in
this section for location of the engine speed sensor
location.
(24) Verify there is a good connection at the Mass
Air Flow Sensor, which is a part of the air intake
assembly.
AIR IN FUEL SYSTEM
Air will enter the fuel system whenever the fuel
supply lines, fuel filter/water separator, fuel filter
bowl, injection pump, high±pressure lines or injectors
are removed or disconnected. Air will also enter the
fuel system whenever the fuel tank has been run
empty.
Air trapped in the fuel system can result in hard
starting, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.
Inspect the fuel system from the fuel tank to the
injectors for loose connections. Leaking fuel is an
indicator of loose connections or defective seals. Air
can also enter the fuel system between the fuel tank
and the injection pump. Inspect the fuel tank and
fuel lines for damage that might allow air into the
system.
For air bleeding, refer to Air Bleed Procedure in
the Service Procedures section of this group.
Fig. 18 Vehicle Speed SensorÐTypical
Fig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Vacuum Pump at Front of Engine
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 11
DIAGNOSIS AND TESTING (Continued)

INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 37).
(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 38). Ensure tab at bottom of sensor locks in
place.
(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel module
electrical connector.
(7) Install fuel module. Refer to Fuel Reservoir
Module in this section.FUEL INJECTION PUMP
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Thoroughly clean the area around the injection
pump and fuel lines of all dirt, grease and other con-
taminants.Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
(3) Remove the engine accessory drive belt. Refer
to Group 7, Cooling System for procedures.
(4) Remove the generator assembly.
(5) Remove the rubber fuel return and supply
hoses from metal lines at pump (Fig. 39).
(6) Remove the electrical connector at engine cool-
ant temperature sensor (Fig. 40).
(7) Disconnect the Fuel Injection Pump electrical
connector at fuel pump. (Fig. 39).
Fig. 36 Level Sensor Removal/Installation
Fig. 37 Groove in Back Side of Level Sensor
Fig. 38 Installation Channel
Fig. 39 Overflow Valve and Fuel Shutdown Solenoid
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 19
REMOVAL AND INSTALLATION (Continued)

(14) Gauge reading should be at 0.60 mm. If not,
the pump must be rotated for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pumpclockwise(as viewed from
front) until .60 mm is indicated on the dial indica-
tor gauge.
(c) Tighten the three pump mounting nuts to 30
N´m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.60 mm. Loosen pump mounting nuts and
readjust if necessary.
(15) Remove dial indicator and adapter tools.
(16) Install access plug and washer to rear of
injection pump.
(17) Install plug at timing gear cover.
(18) Remove dial indicator from valve stem.
(19) Install valve spring and keepers.
(20) Install rocker arm assembly and tighten nuts.
(21) Install and connect the four high±pressure
fuel lines to the fuel injection pump. Also connect
fuel lines at the fuel injectors. For procedures, refer
to High±Pressure Fuel Lines in this group.
(22) Install electrical connector at engine coolant
temperature sensor.
(23) Connect electrical connector at fuel shutdown
solenoid.(24) Connect the main engine wiring harness to
the glow plugs.
(25) Connect the fuel timing solenoid pigtail har-
ness to the engine wiring harness.
(26) Connect the overflow valve/banjo fitting (fuel
return line assembly). Replace copper gaskets before
installing.
(27) Connect the rubber fuel return and supply
hoses to metal lines at pump. Tighten hose clamps to
2 N´m (20 in. lbs.) torque.
(28) Install generator assembly.
(29) Install engine accessory drive belt. Refer to
Group 7, Cooling System for procedures.
(30) Install negative battery cable to battery.
(31) Start the engine and bring to normal operat-
ing temperature.
(32) Check for fuel leaks.
FUEL INJECTORS
Four fuel injectors are used on each engine. Of these
four, two different types are used. The fuel injector used
on cylinder number one is equipped with a fuel injector
sensor (Fig. 47). The other three fuel injectors are iden-
tical.
Do not place the fuel injector equipped with
the fuel injector sensor into any other location
except the cylinder number one position.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Thoroughly clean the area around the injector
with compressed air.
(3) Remove the fuel drain hoses (tubes) at each
injector (Fig. 48) being serviced. Each of these hoses
is slip±fit to the fitting on injector.
(4) Remove the high±pressure fuel line at injector
being removed. Refer to High±Pressure Fuel Lines in
this group for procedures.
(5) Remove the injector using special socket tool
number VM.1012A. When removing cylinder number
Fig. 46 Installing Dial Indicator and Special Adapter
Tools
Fig. 47 Fuel Injector SensorÐNumber±1 Cylinder
14 - 22 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(13) Check the electrical connection at the knock
sensor (Fig. 18).
(14) Check the electrical connections at the cam-
shaft position sensor and engine coolant temperature
sensor (Fig. 19).
(15) Check the electrical connector at the Elec-
tronic EGR Transducer. Inspect the vacuum and back
pressure hoses at the solenoid and transducer for
leaks (Fig. 20).
(16) Inspect the electrical connections at the gen-
erator (Fig. 21). Check the generator belt for glazing
or damage.(17) Inspect the electrical connector at the crank-
shaft position sensor (Fig. 22).
(18) Check the electrical connection at the vehicle
speed sensor (Fig. 23).
Fig. 12 Idle Air Control Motor and Throttle Position
SensorÐTypical
Fig. 13 PCV Valve
Fig. 14 MAP/Intake Air Temperature Sensor
Fig. 15 Fuel Injectors
Fig. 16 Ignition Coil and Spark PlugsÐTypical
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 37
DIAGNOSIS AND TESTING (Continued)

STEERING
CONTENTS
page page
GENERAL INFORMATION................... 1
POWER STEERING GEAR.................. 26POWER STEERING PUMP.................. 9
STEERING COLUMN...................... 36
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION......................... 1DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS..... 2
GENERAL INFORMATION
STEERING SYSTEM AND COMPONENT
DESCRIPTION
The power steering system consists of these four
major components. Power Steering Pump, Power
Steering Gear, Pressure Hose, and Return Line.
Turning of the steering wheel is converted into linear
travel through the meshing of the helical pinion
teeth with the rack teeth. Power assist steering is
provided by an open center, rotary type control valve.
It is used to direct oil from the pump to either side of
the integral steering rack piston.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As requiredsteering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston,
which, in turn, builds up hydraulic pressure and
assists in the turning effort.
Drive tangs on the power steering gear pinion
shaft, mate loosely with the shaft of the steering
gear. This is to allow manual steering control to be
maintained, if the drive belt on the power steering
pump should break. However, under these conditions,
steering effort will significantly increase.
NSSTEERING 19 - 1

DIAGNOSIS AND TESTING
STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There is some noise in all power steering systems. One of the most common is a hissing sound evident at
standstill parking. Hiss is a very high frequency noise similar to that experienced while slowly closing a water
tap. The noise is present in every valve and results from high velocity fluid passing over the edges of the valve
orifice. There is no relationship between this noise and the performance of the vehicles steering system. Hiss
may be expected when the steering wheel is at the end of its travel or slowly turning when the vehicle is at
a standstill.
CONDITION POSSIBLE CAUSES CORRECTION
Objectionable Hiss Or Whistle 1. Damaged or mispositioned
steering column coupler to dash
panel seal.1. Check for proper seal between
steering column coupler and dash
seal.
2. Noisy valve in power steering
gear.2. Replace steering gear assembly.
3. Mis-routed power steering hose 3. Check for proper routing of power
steering hoses and ensure they do
contact other components.
Rattle Or Clunk 1. Steering gear loose on front
suspension crossmember.1. Check steering gear to front
suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
2. Front suspension crossmember to
frame bolts or studs loose.2. Tighten the front suspension
crossmember attaching bolts or
studs to the specified torque.
3. Tie rod is loose (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm to front
suspension crossmember bolts.4. Tighten control arm mounting
bolts to the specified torques.
5. Loose upper control arm/ shock
absorber mounting bracket to body
attaching bolts.5. Check mounting bracket to body
attaching bolts for looseness. If
required tighten to the specified
torques.
6. Power steering fluid pressure
hose touching the body of the
vehicle.6. Adjust hose to proper position by
loosening, repositioning, and
tightening fitting to specified torque.
Do not bend tubing.
7. Noise internal to power steering
gear.7. Replace steering gear assembly.
8. Damaged front suspension
crossmember.8. Replace front suspension
crossmember.
9. Loose stabilizer bar attaching link
mounting nuts.9. Tighten the stabilizer bar attaching
link mounting nuts to the specified
torque.
Chirp or squeal (in the area of the
power steering pump). Particularly
noticeable at full wheel travel and
during standstill parking.1. Loose power steering pump drive
belt.1. Adjust power steering pump drive
belt to specified tension.
19 - 2 STEERINGNS

BINDING STICKING SEIZED
SHAKE SHUDDER VIBRATION
CONDITION POSSIBLE CAUSES CORRECTION
CATCHES, STICKS IN CERTAIN
POSITIONS OR IS DIFFICULT TO
TURN.1. Low power steering fluid level. 1. Fill power steering fluid reservoir
to specified level and perform
leakage diagnosis.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified
pressure.
3. Lack of lubrication in front
suspension lower control arm ball
joints.3. Replace lower ball joint.
4. Worn lower ball joint. 4. Replace the lower ball joint.
5. Lack of lubrication in steering
gear outer tie rod ends.5. Replace tie rod end.
6. Loose power steering pump drive
belt.6. Tighten the power steering pump
drive belt to the specified tension.
See accessory drive in service
manual.
7. Faulty power steering pump flow
control. (Verify cause using Power
Steering Pump Test Procedure.)7. Replace power steering pump.
8. Excessive friction in steering
column or intermediate shaft.8. Correct condition. (See Steering
Column Service Procedure)
9. Steering column coupler binding. 9. Realign the steering column to
eliminate the binding condition.
10. Binding lower ball joint. 10. Replace the lower ball joint.
11. Excessive friction in steering
gear.11. Replace steering gear assembly.
CONDITION POSSIBLE CAUSES CORRECTION
VIBRATION OF THE STEERING
WHEEL AND/OR DASH DURING
DRY PARK OR LOW SPEED
STEERING MANEUVERS.1. Air in the fluid of the power
steering system.1. Steering shudder can be expected
in new vehicles and vehicles with
recent steering system repairs.
Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check the inner to outer tie rod
jam nut for looseness. If loose
tighten to the specified torque.
Inspect inner tie rod for looseness at
steering gear. Inspect outer tie rod
ball for excessive wear/looseness. If
inner tie rod is loose replace steering
gear, if outer tie has excessive wear
replace tie rod end.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis)
19 - 4 STEERINGNS
DIAGNOSIS AND TESTING (Continued)