1996 CHRYSLER VOYAGER light

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.
Powertrain
Control Module
C1BK LT Fender Side
Shield3
Powertrain
Control Module
C2BK LT Fender Side
Shield3
Radiator Fan
No.1BK At Motor N/S
Radiator Fan
No.2BK At Motor N/S
Radiator Fan
RelayBK LT Front Frame
Rail3
Radio C1 GY Rear of Radio 11
Radio C2 BK Rear of Radio 11
Radio C3 BK Rear of Radio 11
Radio Choke LT/GY Rear of Radio N/S
Rear A/C-
Heater UnitLT/GN RT Quarter
Panel22
Rear Blower
Front Control
SwitchBK Rear of Switch 11
Rear Blower
Rear Control
SwitchBK At Switch N/S
Rear Cigar
Lighter/Power
OutletBK LT Quarter
Panel21
Rear Dome
LampBK At Lamp N/S
Rear Washer
MotorBK Bottom of
Reservior4
Rear Window
DefoggerBK On Liftgate 23
Rear Wiper
MotorBK At Motor 23
Recirculation
Door ActuatorNAT RT Side of
HVAC15
Remote Keyless
Entry ModuleRD Top RT of I.P. 11
Right
Combination
RelayBK LT Quarter
PanelN/S
Right Door
Arm/Disarm
SwitchBK At Switch 19
Right Door
Courtesy LampBK At Lamp 19Component/
GroundColor Location Fig.
Right Door
SpeakerBK At Speaker 19
RF3 BK At Radiator Fan
ModuleN/S
Right Fog Lamp GY At Lamp 4
Right Front
Door Ajar
SwitchBK RT B-Pillar 12
Right Front
Door Lock
MotorBK At Motor 19
Right Front
Panel SpeakerBK At Speaker 11
Right Front
Park/Turn
Signal LampBK At Lamp 4
Right Front
Wheel Speed
SensorBK Right Fender
Side Shield4
Right Front
Window MotorRD At Motor 19
Right Headlamp BK At Lamp 4
Right Headlamp
Leveling MotorBK At Motor N/S
Right Liftgate
Flood LampBK At Lamp 23
Right Mid
Reading LampGY At Lamp 17
Right Power
Door Lock
SwitchBK At Switch 19
Right Power
Mirror C1RD At Mirror 11
Right Power
Mirror C2BL At Mirror 11
Right Power
Window SwitchBK At Switch 19
Right Rear
Lamp AssemblyBK At Lamp 22
Right Rear Door
Ajar SwitchBK RT C-Pillar N/S
Right Rear Pillar
SpeakerBK At Speaker 22
Right Rear
Reading LampGY At Lamp 17
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 35
DESCRIPTION AND OPERATION (Continued)

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)

(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes, using a light honing oil.Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 2).(4) A controlled hone motor speed between
200-300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50-60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
NSENGINE 9 - 3
GENERAL INFORMATION (Continued)

(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
(6) Disconnect the fresh air hose (makeup air) at
the cylinder head cover and plug or cap the nipple on
the cover.
(7) Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
(10) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(11) If no leaks are detected, turn off the air sup-
ply and remove the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed
to next step.
(12) Clean the oil off the suspect oil leak area
using a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil galley cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified. Refer to Rear
Crankshaft Seals, for proper replacement procedures.
NSENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary.Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. Test starting system. Refer to Group
8B, Starting.
4. Moisture on ignition wires. 4. Remove moisture from wires.
5. Faulty ignition cables. 5. Replace any cracked or shorted
cables.
6. Faulty coil or control unit. 6. Test and replace as needed.
Refer to Group 8D, Ignition System
7. Incorrect spark plug gap. 7. Set gap. Refer to Group 8D,
Ignition System.
8. Contamination in fuel system. 8. Clean system and replace fuel
filter.
9. Faulty fuel pump. 9. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses. Refer to
Group 11, Exhaust System and
Intake Manifold.
4. Incorrect ignition wiring. 4. Install correct wiring.
5. Faulty coil(s) 5. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Install new parts, as necessary.
9. Faulty ignition cables. 9. Replace any cracked or shorted
cables.
10. Faulty coil(s). 10. Test and replace as necessary.
Refer to Group 8D, Ignition System.
9 - 10 ENGINENS
DIAGNOSIS AND TESTING (Continued)

(2) Inspect the remaining margin after the valves
are refaced (Fig. 18). Intake valves with less than 1.2
mm (3/64 inch.) margin and Exhaust valves with less
than 0.9 mm (1/32 inch.) margin should be discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.²Intake valve seat diameter is 34.37 34.63 mm
(1.158 1.363 inch.)
²Exhaust valve seat diameter is 29.37 29.63 mm
(1.156 1.166 inch.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.9 to 1.3 mm
(0.35 to 0.051 inch.) (Fig. 19).
(8) Check valve tip height dimensions A after
grinding the valve seats or faces (Fig. 20). Grind
valve tip to 47.99 mm (1.889 in.) for exhaust valve
and 48.04 mm (1.891 in.) for intake valve when
installed in the head. The valve tip chamfer may
Fig. 17 Testing Valve Springs
Intake and Exhaust Valves
VALVE SPECIFICATION CHART
Face Angle
Intake and Exhaust: 44.5É-45É
Head Diameter
Intake: 34.67 - 34.93 mm
(1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length (Overall)
Intake: 112.76 - 113.32 mm
(4.439 - 4.461 in.)
Exhaust: 109.59 - 110.09 mm
(4.314 - 4.334 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm
(0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm
(0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.285 - 1.615 mm
(0.050 - 0.063 in.)
Exhaust: 0.985 - 1.315 mm
(0.038 - 0.051 in.)
Fig. 18 Refacing Intake and Exhaust Valves
9 - 22 2.4L ENGINENS
SERVICE PROCEDURES (Continued)

(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Install crankshaft sprocket using Special Tool
6052 (Fig. 44).
(5) Turn crankshaft until number one cylinder is
at Top Dead Center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 45).
(6) Place chain over crankshaft sprocket so that
the nickel plated link of the chain is over the number
1 cylinder timing mark on the crankshaft sprocket
(Fig. 45).
(7) Place balance shaft sprocket into the timing
chain (Fig. 45) so that the timing mark on the
sprocket (yellow dot) mates with the (lower) nickel
plated link on the chain
(8) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the noseof the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 42 Balance Shaft(s)ÐRemoval/Installation
Fig. 43 Gear Timing
Fig. 44 Crankshaft SprocketÐInstallation
Fig. 45 Balance Shaft Timing
9 - 32 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)