1996 CHRYSLER VOYAGER fuel

(6) Disconnect idle air control motor and Throttle
Position Sensor (TPS) electrical connectors (Fig. 44).
(7) Remove vacuum hose harness from throttle
body and intake manifold (Fig. 45).
(8) Remove EGR tube to intake manifold flange
bolts (Fig. 46).
(9) Remove cylinder head to intake plenum strut.
(10) Disconnect electrical connector from the MAP
sensor (Fig. 47)(11) Remove engine mounted ground strap.
(12) Remove the fuel hose quick connect fitting
from the chassis tube (Fig. 48).Refer to Fuel
Hoses, Clamps and Quick Connect Fittings in
this Section.
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 43 Throttle Cable Attachment
Fig. 44 Electrical and Vacuum Connection to
Throttle Body
Fig. 45 Vacuum Connections
Fig. 46 EGR TubeÐ3.3L/3.8
14 - 22 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(13) Remove Direct Ignition System (DIS) coils
(Fig. 49).
(14) Remove generator bracket to intake manifold
bolt.(15) Remove intake mounting manifold bolts and
rotate manifold back over rear valve cover (Fig. 50).
(16) Cover intake manifold with suitable cover
when servicing (Fig. 51).
(17) Remove fuel tube retainer bracket screw and
fuel rail attaching bolts (Fig. 51). Spread the retainer
bracket to allow fuel tube removal clearance.
(18) Disconnect camshaft position sensor (Fig. 52)
and engine coolant temperature sensor.
(19) Remove fuel rail. Be careful not to damage
the injector O-rings upon removal from their ports
(Fig. 53).
INSTALLATION
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
Fig. 47 Map Sensor
Fig. 48 Fuel Line Quick Disconnect
Fig. 49 Ignition Coils
Fig. 50 Intake Manifold Bolts
Fig. 51 Fuel Rail Attaching Bolts
NSFUEL SYSTEM 14 - 23
REMOVAL AND INSTALLATION (Continued)

(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque (Fig. 51).
(5) Install fuel tube retaining bracket screw.
Tighten screw to 4 N´m (35 in. lbs.) torque.
(6) Connect electrical connectors to camshaft posi-
tion sensor and engine coolant temperature sensor.
(7) Remove covering on lower intake manifold and
clean surface.
(8) Place intake manifold gasket on lower mani-
fold. Put upper manifold into place and install bolts
finger tight.
(9) Install the generator bracket to intake mani-
fold bolt and the cylinder head to intake manifold
strut bolts (do not tighten.)(10) Following the tightening sequence in (Fig. 50),
tighten intake manifold bolts to 28 N´m (250 in. lbs.)
torque.
(11) Tighten generator bracket to intake manifold
bolt to 54 N´m (40 ft. lbs.) torque.
(12) Tighten the cylinder head to intake manifold
strut bolts to 54 N´m (40 ft. lbs.) torque.
(13) Connect ground strap and MAP sensor electri-
cal connector.
(14) Connect vacuum harness to intake plenum.
Connect PCV system hoses.
(15) Using a new gasket, connect the EGR tube to
the intake manifold plenum. Tighten screws to 22
N´m (200 in. lbs.) torque.
(16) Connect electrical connectors to the TPS and
idle air control motor.
(17) Connect vacuum harness to throttle body.
(18) Install the direct ignition system (DIS) coils.
Tighten fasteners to 12 N´m (105 in. lbs.) torque.
(19) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(20) Install throttle cable and speed control cable
(if equipped).
(21) Install air inlet resonator.
(22) Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(23) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
FUEL INJECTORÐ2.4L
The fuel rail must be removed first. Refer to Fuel
Injector Rail Removal in this section.
REMOVAL
(1) Disconnect injector wiring connector from injec-
tor.
(2) Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 54).
(3) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is dam-
aged.
(5) Repeat for remaining injectors.
Fig. 52 Camshaft Position Sensor Connector
Fig. 53 Fuel Rail Removal
14 - 24 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip.
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 55).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
FUEL INJECTORSÐ3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Release Procedure.
(2) Disconnect negative cable from battery.
(3) The fuel rail must be removed first to service
the injectors. Refer to Fuel Injector Rail Assembly
Removal in this section.
(4) Label each injector connector with its cylinder
number. Disconnect electrical connector from injector.
(5) Position fuel rail assembly so that the fuel
injectors are easily accessible.
(6) Remove injector clip from fuel rail and injector
(Fig. 54).
(7) Pull injector straight out of fuel rail receiver
cup (Fig. 55).
(8) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is to be
reused, a protective cap must be installed on the
injector tip to prevent damage.
(9) Repeat procedure for remaining injectors.
INSTALLATION
(1) Before installing an injector, the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Being careful not to damage O-ring, install
injector nozzle end into fuel rail receiver cap.
(3) Install injector clip by sliding open end into
top slotof the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 55)
(4) Repeat steps for remaining injectors.
(5) Install fuel rail assembly. Refer to Fuel Rail
Assembly Installation in this section.
(6) Connect electrical connectors to injectors in cor-
rect order.
(7) Connect negative battery cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(8) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
Fig. 54 Fuel Injector and RailÐTypical
Fig. 55 Servicing Fuel InjectorÐTypical
NSFUEL SYSTEM 14 - 25
REMOVAL AND INSTALLATION (Continued)

FUEL INJECTORÐ3.3/3.8L
The fuel rail must be removed first. Refer to Fuel
Injector Rail Assembly Removal in this section.
REMOVAL
(1) Disconnect injector wiring connector from injec-
tor.
(2) Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 54).
(3) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is dam-
aged.
(5) Repeat for remaining injectors.
INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 56).
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 56).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Working from the engine compartment, remove
the throttle control shield.
(2) Hold the throttle body throttle lever in the
wide open position. Remove the throttle cable from
the throttle body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 57) and (Fig. 58).
(4) Working from the engine compartment, remove
nuts from accelerator pedal attaching studs (Fig. 57).
Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts
to 12 N´m (105 in. lbs.) torque.
Fig. 56 Servicing Fuel InjectorÐTypical
Fig. 57 Accelerator Pedal and Throttle CableÐFront
View
Fig. 58 Accelerator Pedal and Throttle CableÐRear
View
14 - 26 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(2) From inside the vehicle, hold up the pedal and
install the throttle cable and cable retainer in the
upper end of the pedal shaft.
(3) From the engine compartment, hold the throt-
tle body lever in the wide open position and install
the throttle cable. Install the throttle control shield.
THROTTLE CABLE
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open posi-
tion.
(2) Remove the throttle cable from the throttle
body cam (Fig. 59), (Fig. 60) and (Fig. 61).
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 57).
(4) Remove retainer clip from throttle cable and
grommet at dash panel (Fig. 58).
(5) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
(6) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta-
neously. Then gently pull the throttle cable from
throttle bracket.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet.
(2) Install the cable housing (throttle body end)
into the cable mounting bracket on the engine.(3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
end of the pedal shaft.
(4) At the dash panel, install the cable retainer
clip between the end of the throttle cable fitting and
grommet (Fig. 58)
(5) From the engine compartment, rotate the
throttle lever wide open and install the throttle
cable.
Fig. 59 Throttle Cable Attachment to Throttle Body
AttachmentÐ2.4L Engine
Fig. 60 Throttle Cable Attachment to Throttle Body
AttachmentÐ3.0L Engine
Fig. 61 Throttle Cable Attachment to Throttle Body
AttachmentÐ3.3/3.8L Engines
NSFUEL SYSTEM 14 - 27
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Fuel Pump Module Locknut.....58N´m(43ft.lbs.)
Fuel Tank Strap Bolts.........54N´m(40ft.lbs.)
Fuel Rail BoltsÐ2.4L........22N´m(200 in. lbs.)
Fuel Rail BoltsÐ3.0L.........13N´m(115in.lbs.)
Fuel Rail BoltsÐ3.3/3.8L.......10N´m(95in.lbs.)
Fuel Tube Holddown BoltsÐ3.0L..........22N´m
(200 in. lbs.)
Fuel Tube Holddown Screw......4N´m(35in.lbs.)
Intake Manifold BoltsÐ2.4L . . .22 N´m (200 in. lbs.)
Intake Manifold BoltsÐ3.0L . . .13 N´m (115 in. lbs.)
Intake Manifold BoltsÐ3.3/3.8L...........28N´m
(250 in. lbs.)
Accelerator Pedal to Dash Nuts...........12N´m
(105 in. lbs.)
FUEL TANK CAPACITY
Vehicle Liters U.S. Gallons
NS 75.O 20
Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
14 - 28 FUEL SYSTEMNS

FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 30
MODES OF OPERATION.................. 30
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CLUTCH RELAYÐ
PCM OUTPUT......................... 41
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT............. 33
AIR CONDITIONING SWITCH SENSEÐ
PCM INPUT........................... 33
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT........................... 33
AUTOMATIC SHUTDOWN RELAYÐPCM
OUTPUT............................. 42
AUTOMATIC TRANSAXLE CONTROL
MODULEÐPCM OUTPUT................ 44
BATTERY VOLTAGEÐPCM INPUT........... 33
BRAKE SWITCHÐPCM INPUT.............. 33
CAMSHAFT POSITION SENSORÐPCM INPUT . 33
CCDBUS .............................. 32
CRANKSHAFT POSITION SENSORÐPCM
INPUT............................... 35
DATA LINK CONNECTORÐPCM OUTPUT..... 44
DUTY CYCLE EVAP CANISTER PURGE
SOLENOIDÐPCM OUTPUT.............. 43
ELECTRONIC EGR TRANSDUCER
SOLENOIDÐPCM OUTPUT.............. 43
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT........................... 36
FUEL INJECTORSÐPCM OUTPUT.......... 44
FUEL PUMP RELAYÐPCM OUTPUT......... 42
GENERATOR FIELDÐPCM OUTPUT......... 42
HEATED OXYGEN SENSOR (O2S SENSOR)Ð
PCM INPUT........................... 37
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . 42
IGNITION COILÐPCM OUTPUT............. 45
INTAKE AIR TEMPERATURE SENSORÐPCM
INPUT (2.4L ONLY)..................... 41
KNOCK SENSORÐPCM INPUT............. 38
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT.................. 46
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT.................. 39
POWERTRAIN CONTROL MODULE (PCM).... 32
PROPORTIONAL PURGE SOLENOID......... 43
SOLID STATE FAN RELAYÐPCM OUTPUT.... 46
SPEED CONTROL SOLENOIDSÐ
PCM OUTPUT......................... 46
SPEED CONTROLÐPCM INPUT............ 39STARTER RELAYÐPCM OUTPUT........... 42
SYSTEM DIAGNOSIS..................... 32
TACHOMETERÐPCM OUTPUT............. 47
THROTTLE BODY....................... 47
THROTTLE POSITION SENSOR (TPS)Ð
PCM INPUT........................... 40
TORQUE CONVERTER CLUTCH SOLENOIDÐ
PCM OUTPUT......................... 46
TRANSAXLE PARK/NEUTRAL SWITCHÐ
PCM INPUT........................... 40
VEHICLE SPEED AND DISTANCEÐ
PCM INPUT........................... 41
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS............. 59
CAMSHAFT AND CRANKSHAFT POSITION
SENSOR............................. 61
ENGINE COOLANT TEMPERATURE SENSOR . . 61
HEATED OXYGEN SENSOR............... 61
KNOCK SENSOR........................ 61
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 60
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE................... 62
THROTTLE POSITION SENSOR............ 62
VISUAL INSPECTIONÐ2.4L ENGINE......... 47
VISUAL INSPECTIONÐ3.0L ENGINE......... 52
VISUAL INSPECTIONÐ3.3/3.8L ENGINES..... 55
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT.................. 70
AUTOMATIC SHUTDOWN (ASD) RELAY...... 64
CAMSHAFT POSITION SENSOR............ 68
CRANKSHAFT POSITION SENSOR.......... 68
DOWNSTREAM OXYGEN SENSOR.......... 69
ENGINE COOLANT TEMPERATURE
SENSORÐ2.4L........................ 70
ENGINE COOLANT TEMPERATURE
SENSORÐ3.0L........................ 71
ENGINE COOLANT TEMPERATURE
SENSORÐ3.3/3.8L..................... 71
FUEL PUMP RELAY...................... 64
IDLE AIR CONTROL MOTOR............... 65
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 72
KNOCK SENSOR........................ 70
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ2.4/3.3/3.8L.................. 66
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ3.0L........................ 66
POWERTRAIN CONTROL MODULE.......... 67
PROPORTIONAL PURGE SOLENOID VALVE . . . 66
NSFUEL SYSTEM 14 - 29