1996 CHRYSLER VOYAGER check oil

FUEL INJECTION SYSTEMÐ2.0L ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTIONÐ2.0L ENGINE............ 32
MODES OF OPERATIONÐ2.0L ENGINE..... 32
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) RELAYÐPCM
OUTPUTÐ2.0L ENGINE................ 35
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUTÐ
2.0L ENGINE......................... 33
AIR CONDITIONING SWITCH SENSEÐ
PCM INPUTÐ2.0L ENGINE.............. 33
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUTÐ2.0L ENGINE.............. 33
AUTOMATIC SHUTDOWN RELAYÐ
PCM OUTPUTÐ2.0L ENGINE............ 35
BATTERY VOLTAGEÐPCM INPUTÐ
2.0L ENGINE......................... 33
CAMSHAFT POSITION SENSORÐ
PCM INPUTÐ2.0L ENGINE.............. 33
CRANKSHAFT POSITION SENSORÐ
PCM INPUTÐ2.0L ENGINE.............. 33
DATA LINK CONNECTORÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
ELECTRONIC EGR TRANSDUCERÐ
PCM OUTPUTÐ2.0L ENGINE............ 35
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUTÐ2.0L ENGINE.............. 33
FUEL INJECTORSÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
FUEL PUMP RELAYÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
GENERATOR FIELDÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
HEATED OXYGEN SENSORÐPCM INPUTÐ
2.0L ENGINE......................... 33
IDLE AIR CONTROL MOTORÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
IGNITION COILÐPCM OUTPUTÐ
2.0L ENGINE......................... 36KNOCK SENSORÐPCM INPUTÐ
2.0L ENGINE......................... 34
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUTÐ2.0L ENGINE...... 36
MANIFOLD ABSOLUTE PRESSURE
(MAP SENSOR)ÐPCM INPUTÐ
2.0L ENGINE......................... 34
POWERTRAIN CONTROL MODULEÐ
2.0L ENGINE......................... 33
RADIATOR FAN CONTROL MODULEÐ
PCM OUTPUTÐ2.0L ENGINE............ 36
SPEED CONTROL SOLENOIDSÐ
PCM OUTPUTÐ2.0L ENGINE............ 36
SPEED CONTROLÐPCM INPUTÐ
2.0L ENGINE......................... 34
STARTER RELAYÐPCM OUTPUTÐ
2.0L ENGINE......................... 35
SYSTEM DIAGNOSISÐ2.0L ENGINE........ 33
TACHOMETERÐPCM OUTPUTÐ
2.0L ENGINE......................... 36
THROTTLE BODYÐ2.0L ENGINE.......... 36
THROTTLE POSITION SENSOR/ IDLE AIR
CONTROL MOTORÐPCM INPUTÐ
2.0L ENGINE......................... 35
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYSÐ
2.0L ENGINE......................... 39
CAMSHAFT AND CRANKSHAFT
POSITION SENSOR................... 40
ENGINE COOLANT TEMPERATURE
SENSOR............................ 40
KNOCK SENSORÐ2.0L ENGINE........... 40
MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSORÐ2.0L ENGINE........... 39
THROTTLE BODY MINIMUM AIR FLOW..... 41
THROTTLE POSITION SENSOR........... 40
VISUAL INSPECTIONÐSOHC............. 36
SPECIFICATIONS
TORQUE............................. 42
GENERAL INFORMATION
INTRODUCTIONÐ2.0L ENGINE
Refer to the Introduction for 2.4/3.0/3.3/3.8L
engines under General Information in the Fuel Injec-
tion System section of group 14 for more information.
MODES OF OPERATIONÐ2.0L ENGINE
Refer to the Modes of Operation for 2.4/3.0/3.3/3.8L
engines under General Information in the Fuel Injec-
tion System section of group 14 for more information.
14 - 32 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

IGNITION COILÐPCM OUTPUTÐ2.0L ENGINE
Refer to the Ignition Coil for 2.4/3.0/3.3/3.8L
engines under Description and Operation in the Fuel
Injection System section of group 14 for more infor-
mation.
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUTÐ2.0L ENGINE
Refer to the Malfunction Indicator Lamp for 2.4/
3.0/3.3/3.8L engines under Description and Operation
in the Fuel Injection System section of group 14 for
more information.
RADIATOR FAN CONTROL MODULEÐPCM
OUTPUTÐ2.0L ENGINE
Refer to the Radiator Fan Control Module for 2.4/
3.0/3.3/3.8L engines under Description and Operation
in the Fuel Injection System section of group 14 for
more information.
SPEED CONTROL SOLENOIDSÐPCM OUTPUTÐ
2.0L ENGINE
Refer to the Speed Control Solenoids for 2.4/3.0/3.3/
3.8L engines under Description and Operation in the
Fuel Injection System section of group 14 for more
information.
TACHOMETERÐPCM OUTPUTÐ2.0L ENGINE
Refer to the Tachometer for 2.4/3.0/3.3/3.8L engines
under Description and Operation in the Fuel Injec-
tion System section of group 14 for more information.
THROTTLE BODYÐ2.0L ENGINE
Refer to the Throttle Body for 2.4/3.0/3.3/3.8L
engines under Description and Operation in the Fuel
Injection System section of group 14 for more infor-
mation.
DIAGNOSIS AND TESTING
VISUAL INSPECTIONÐSOHC
Before diagnosing or servicing the fuel injection
system, perform a visual inspection for loose, discon-
nected, or misrouted wires and hoses. A thorough
visual inspection that includes the following checks
saves unnecessary test and diagnostic time.
(1) Inspect the battery connections. Clean corroded
terminals.
(2) Check the 2 PCM 40-way connector for
stretched wires on pushed out terminals
(3) Open the Power Distribution Center (PDC).
Check for blown fuses. Ensure the relays and fuses
are fully seated in the PDC. A label on the underside
of the PDC cover shows the locations of each relay
and fuse.
(4) Verify the throttle cable operates freely.
(5) Check the electrical connections at the idle air
control motor and throttle position sensor.
(6) Check hose connections between the PCV
valve, vacuum port - intake manifold and the oil sep-
arator (Fig. 13).
(7) Inspect the electrical connections at the MAP
sensor/intake air temperature sensor and the (Fig.
14).
(8) Inspect the fuel injector electrical connections
(Fig. 15).
(9) Inspect the ignition coil electrical connector.
Ensure the spark plug insulators are firmly seated
over the spark plugs (Fig. 16).
(10) Check the electrical connection to the radiator
fan.
(11) Inspect for corrosion on the electrical connec-
tions at the starter motor solenoid. Check the ground
cable connection below the starter motor (Fig. 17).
(12) Inspect the air cleaner filter element. Replace
as necessary. Check the air induction system for
restrictions.
Fig. 10 Ignition CoilÐ2.0L engine
Fig. 11 Throttle BodyÐ2.0L engine
14 - 36 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DESCRIPTION AND OPERATION (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)

In this chart, Pre±Heat and Post±Heat times are
mentioned. Pre±heat is the amount of time the glow
plug relay circuit is activated when the ignition (key)
switch is ON, but the engine has yet to be started.
Post±heat is the amount of time the glow plug relay
circuit is activated after the engine is operating. The
Glow Plug lamp will not be illuminated during the
post±heat cycle.
TESTING:
Disconnect and isolate the electrical connectors
(Fig. 16) at all four glow plugs. With the engine cool
or cold, and the key in the ON position, check for
10±12 volts + at each electrical connector. 10±12 volts
+ should be at each connector whenever the PCM is
operating in the pre±heat or post±heat cycles (refer
to the following Glow Plug Control chart).Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors.If 10±12
volts + is not available at each connector, check con-
tinuity of wiring harness directly to the relay. If con-
tinuity is good directly to the relay, the fault is either
with the relay or the relay input from the PCM. To
test the relay only, refer to RelaysÐOperation/Test-
ing in this section of the group. If the relay test is
good, refer to the DRB scan tool.
Diagnostic Trouble Codes:Refer to On-Board
Diagnostics in Group 25, Emission Control System
for a list of Diagnostic Trouble Codes (DTC's) for cer-
tain fuel system components.
RELAYSÐOPERATION/TESTING
The following description of operation and
tests apply only to the Diesel PCM and other
relays. The terminals on the bottom of each relay
are numbered (Fig. 17).
OPERATION
²Terminal number 30 is connected to battery volt-
age. For both the Diesel and other relays, terminal
30 is connected to battery voltage at all times.
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 Diesel PCM
and other relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off posi-
tion, voltage is not supplied to the rest of the circuit.
Terminal 87A is the center terminal on the relay.
Fig. 15 Glow Plug Relay Location
Fig. 16 Wiring Connection at Glow Plug
GLOW PLUG CONTROL
14 - 52 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise
should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing
aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
WHINE OR GROWL (PUMP
NOISE)1. Low fluid level. 1. Fill power steering fluid
reservoir to proper level and
perform leakage diagnosis.
(Recheck fluid level after power
steering fluid is free of air.)
2. Power steering hose touching
vehicle body or frame.2. Reposition power steering
hose. Replace hose if tube ends
are bent.
3. Extreme wear of power
steering pump internal parts.3. Replace power steering pump
and flush system.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid low pressure hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power
steering pressure hose
connection.2. Inspect connection and replace
O-Ring as required.
3. Low power steering fluid level 3. Fill power steering fluid
reservoir to proper level and
perform leakage diagnosis.
4. Air leak between power
steering fluid reservoir and power
steering pump.4. Inspect and/or replace power
steering fluid reservoir or supply
hose as required.
SQUEAK OR RUBBING
SOUND1. Sound coming from steering
column.1.Check for squeak in steering
column. Inspect for contact
between shroud, intermediate
shaft, column, and steering wheel.
Realign if necessary.Note: Check
steering column for noise
without clockspriing installed
and with the steering column
shaft removed from the steering
intermediate shaft. This must be
done before removing the
steering column for a noise
complaint.
2. Check for lack or grease on
steering column dash panel to
lower coupler seal.
2.Clockspring 3. Replace Clockspring
3. Sound internal to steering gear. 4. Replace steering gear
assembly.
SCRUBBING OR KNOCKING
SOUND1. Incorrect tire size. 1. Verify that tire size on vehicle is
the same as originally supplied.
2. Check clearance between tires
and other vehicle components,
through the full travel of the
suspension.2. Correct as necessary.
3. Check for interference between
steering gear and other
components.3.Correct as necessary.
4.Incorrect steering gear supplied. 4. Replace steering gear with
correct steering gear for specific
vehicle.
NSSTEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)

(18) Remove the 3 previously loosened bolts
attaching the front bracket to the power steering
pump and separate the power steering pump from
the front bracket prior to removing the pump from
the vehicle.
(19) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket and loosely install nut to hold
pump in place (Fig. 9).
(3) Install the front bracket on the power steering
pump and loosely install the 3 mounting bolts (Fig.
10). Then install the nut and bolt attaching the front
bracket to the cast bracket (Fig. 10).
(4) Tighten the 3 power steering pump mounting
bolts (Fig. 10) to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(5) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 8). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(6) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 8).Be sure hose clamps are properly
reinstalled.
(7) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 7).Be sure hose is
clear of accessory drive belts all hose clamps
are properly reinstalled.
(8) Install the power steering pump drive belt on
pulley. See Cooling, Group 7 for detailed installation
procedure.
(9) Install the accessory drive splash shield (Fig.
6).
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 5).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is requiredto prevent the overheating of the power steering
hoses.
(12) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 5).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(13) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(14) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(15) Lower vehicle.
(16) Adjust the power steering pump drive belt.
See Cooling, Group 7 for detailed adjustment proce-
dure.
(17) Tighten the top nut and bottom bolt on the
power steering pump front mounting bracket (Fig. 3)
to a torque of 54 N´m (40 ft. lbs.).
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(18) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(19) Install cap on power steering fluid reservoir.
(20) Connect the negative battery cable on the
negative battery post.
(21) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.0 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
NSSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.
(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.3/3.8 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(7) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 17).
(8) Raise the heat sleeve on the power steering
hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle (Fig. 18).
Allow the remaining power steering fluid to drain
from the pump and fluid reservoir through the
removed return hose.
(9) Remove the accessory drive splash shield (Fig.
19).
Fig. 17 Exhaust Position For Removing Power
Steering Pump
Fig. 18 Power Steering Return Hose At Return Line
Fig. 19 Accessory Drive Splash Shield
19 - 16 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(6) Lower vehicle.
(7) Remove hose clamp attaching the power steer-
ing fluid supply hose to the power steering fluid res-
ervoir (Fig. 24).
(8) Remove the power steering fluid supply hose
from the vehicle. Hose is removed from the top of the
engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must
be routed tightly against the strut tower and parallel
to the dash panel. It must also be routed under the
wiring harness and below the drip tube. This rout-
ing will prevent the power steering fluid supply
hose from coming in contact with the accessory
drive belt.
(1) Install and correctly route the power steering
fluid supply hose from remote fluid reservoir down to
power steering pump.
(2) Install the fluid supply hose onto the power
steering fluid reservoir (Fig. 24). Install the hose
clamp on the fluid supply hose.Be sure hose clamp
is installed past bead on fluid reservoir fitting.
(3) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(4) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose.Be sure hose clamp is installed
past bead on pump fitting.
(5) Lower vehicle.
(6) Install routing clip on power steering fluid sup-
ply hose. Be sure routing clip is installed in a posi-
tion to correctly align with stud in strut tower.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 25).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
POWER STEERING FLUID PRESSURE HOSE
Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
pump fittings and steering gear ports to prevent
entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part location for the vehicle
that is being serviced, refer to the following figure
numbers. These show the hose bracket locations,
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers
when referring to the removal or installation proce-
dures for the power steering hoses listed below.
REMOVE
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve on the power steering
fluid return hose (Fig. 26) to expose the return hose
to steel tube connection. Remove the hose clamp from
the power steering fluid return hose (Fig. 26).
Remove power steering fluid return hose from steel
tube and allow power steering fluid to drain from
pump.
NSSTEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)