1996 CHRYSLER VOYAGER torque

(2) Tighten intake manifold fasteners in the fol-
lowing sequence (Fig. 16). Torque to 23 N´m (200 in.
lbs.). Repeat this procedure until all bolts are at
specified torque.
(3) Install intake manifold center support bracket
bolts (Y bracket):
²Fastener to block 54 N´m (40 ft. lbs.)
²Fastener to intake 28 N´m (250 in. lbs.)
(4) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in Group 14, Fuel Deliv-
ery.Push the fitting onto the chassis tube until it
clicks into place. Pull on the fitting to ensure com-
plete insertion.
(5) Reverse removal procedures 2 through 12 for
installation.
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.
(6) 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.
EXHAUST MANIFOLDÐ2.4L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold at the flex-joint.
(2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 17).
(3) Remove the bolts attaching the manifold to the
cylinder head. Remove manifold (Fig. 17).
(4) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Install exhaust manifold with a new gasket
and tighten attaching nuts in the order shown in
(Fig. 17) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten bolt to 28 N´m (250 in. lbs.).
(3) Connect heated oxygen sensor lead (Fig. 17).
INTAKE MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. See Cooling System, Group 7.
(3) Remove air inlet resonator to throttle body
hose.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 18).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 19).
(6) Remove vacuum hose harness from throttle
body.
(7) Remove PCV and Brake booster hoses from
Air Intake Plenum.
(8) Remove Ignition Coil from Intake Plenum
(Fig. 20).
(9) Remove wiring connectors from coolant temper-
ature sensor (Fig. 21).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hose from fuel rail (Fig. 21).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 17 Exhaust Manifold Attaching PointsÐ2.4L
Engine
Fig. 18 Throttle Cable Attachment
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(16) Remove fuel rail attaching bolts and lift fuel
rail assembly from intake manifold.
(17) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe.
(18) Remove nut and washer assemblies and
remove intake manifold (Fig. 25).
(19) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Position new intake manifold gaskets on cylin-
der head and install intake (cross) manifold.
(2) Install nuts and washers and tighten in sev-
eral steps in order shown in (Fig. 26) to 20 N´m (174
in. lbs.).
(3) Make sure the injector holes are clean and all
plugs have been removed.
(4) Lube injector O-ring with a drop of clean
engine oil to ease installation.
(5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(6) Install the fuel rail attaching bolts and torque
to 13 N´m (115 in. lbs.).(7) Install fuel supply and the vacuum crossover
tube hold-down bolt and torque to 10 N´m (95 in.
lbs.).
(8) Remove covering from lower intake manifold
and clean surface.
(9) Place intake manifold gasketswith beaded
sealant side upon lower manifold. Put air intake in
place. Install attaching fasteners and tighten in sev-
eral steps in sequence shown (Fig. 27) to 13 N´m (115
in. lbs.).
Fig. 25 Intake and Exhaust Manifolds Ð 3.0L Engine
Fig. 26 Fastener Tightening Sequence for Intake
(Cross) Manifold
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(10) Connect fuel line to fuel rail (Fig. 21). Torque
hose clamps to 1 N´m (10 in. lbs.).
(11) Connect vacuum harness to air intake ple-
num.
(12) Connect and coolant temperature sensor elec-
trical connector to sensor (Fig. 21).
(13) Connect PCV and brake booster supply hose
to intake plenum.
(14) Connect automatic idle speed (AIS) motor
and throttle position sensor (TPS) electrical connec-
tors (Fig. 19).
(15) Connect vacuum vapor harness to throttle
body (Fig. 19).
(16) Install throttle cable and transaxle kickdown
linkage (Fig. 18).
(17) Install air inlet resonator hose assembly to
throttle body.
(18) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple.
(19) Fill cooling system. Refer to Filling the Cool-
ing System outlined in Group 7 Cooling System for
procedure.
(20) Connect negative battery cable.
(21) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe
from rear (cowl side) exhaust manifold at the flex-
joint.(2) Disconnect Oxygen Sensor lead wire at the
rear exhaust manifold (Fig. 28).
(3) Remove bolts attaching cross-over pipe to
manifold (Fig. 30).
(4) Remove rear heat shield (Fig. 29).
(5) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
(6) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 31).
(7) Remove bolts fastening crossover pipe to front
exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.
(8) Inspect and clean manifolds. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
Install the gaskets with the numbers 1-3-5
embossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
32).
(1) Install rear exhaust manifold and tighten
attaching nuts to 20 N´m (175 in. lbs.).
Fig. 27 Intake Plenum Tightening Sequence
Fig. 28 Disconnect Up Stream Heated Oxygen
Sensor Connection
Fig. 29 Rear Exhaust Manifold Heat Shield
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

(25) Remove intake manifold bolts. Remove intake
manifold.
(26) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(27) Remove intake manifold seal retainers screws
(Fig. 43). Remove intake manifold gasket.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Place a drop (approximately 1/4 in. diameter)
of MopartSilicone Rubber Adhesive Sealant or
equivalent, onto each of thefourmanifold to cylinder
head gasket corners (Fig. 44).(3) Carefully install the new intake manifold gas-
ket (Fig. 43). Torque end seal retainer screws to 12
N´m (105 in. lbs.).
(4) Install intake manifold and bolts and torque to
1 N´m (10 in. lbs.). Then torque bolts to 22 N´m (200
in. lbs.) in sequence shown in (Fig. 42). Then torque
again to 22 N´m (200 in. lbs.). After intake manifold
is in place,inspect to make sure seals are in
place.
Fig. 38 Intake Manifold Plenum Bolts and Nuts
Fig. 39 Fuel Rail Attaching Bolts
Fig. 40 Coolant Temperature Sensor Electrical
Connector
Fig. 41 Fuel Rail Removal
11 - 14 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(5) Make sure the injector holes are clean and all
plugs have been removed.
(6) Lube injector O-ring with a drop of clean
engine oil to ease installation.(7) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports (Fig. 41).
(8) Install the fuel rail attaching bolts and torque
to 22 N´m (200 in. lbs.) (Fig. 39).
(9) Install fuel tube retaining bracket screw and
torque to 4 N´m (35 in. lbs.) (Fig. 39).
(10) Connect cam sensor and coolant temperature
sensor (Fig. 40).
(11) Remove covering on lower intake manifold
and clean surface.
(12) Place the new intake manifold gasket on
lower manifold. Put upper manifold into place and
install bolts and nuts finger tight.
NOTE: At no time should the studs be replaced
with a bolt and washer.
(13) Install the generator bracket to intake mani-
fold bolt and the cylinder head to intake manifold
strut bolts. (Do not torque.)
(14) Torque intake manifold bolts to 28 N´m (250
in. lbs.) following torque sequence in (Fig. 38).
(15) Torque generator bracket to intake manifold
bolt to 54 N´m (40 ft. lbs.).
(16) Torque the cylinder head to intake manifold
strut bolts to 54 N´m (40 ft. lbs.) (Fig. 35).
(17) Connect ground strap and MAP sensor electri-
cal connectors.
(18) Connect vacuum harness to intake plenum
(Fig. 34).
(19) Using a new gasket, connect the EGR tube
flange to the intake manifold and torque to 22 N´m
(200 in. lbs.).
(20) Clip wiring harness into the hole in the throt-
tle cable bracket.
(21) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor (Fig. 33).
(22) Connect vacuum harness to throttle body (Fig.
33).
(23) Install the direct ignition system (DIS) coils.
Torque fasteners to 12 N´m (105 in. lbs.) (Fig. 37).
(24) Lubricate the end of the chassis fuel tube
with 30 wt. oil. Connect fuel supply hose to chassis
fuel tube assembly. Pull back on the quick connect
fitting to ensure complete insertion (Fig. 36). (Refer
to Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems).
(25) Install throttle cable. Refer to Group 14 Fuel
System for procedure.
(26) Connect fuel injector wiring harness.
(27) Install air cleaner and hose assembly.
(28) Connect negative battery cable. Fill Cooling
System. See Cooling System, Group 7.
(29) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 42 Intake Manifold Removal and Installation
Fig. 43 Intake Manifold Gasket
Fig. 44 Intake Manifold Gasket Sealing
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Band Clamp (Torca)
Fastener..................75N´m(55ft.lbs.)
Exhaust ManifoldÐ2.4L
Fastener.................23N´m(200 in. lbs.)
Exhaust ManifoldÐ3.0L
Nuts....................22N´m(191 in. lbs.)
Exhaust ManifoldÐ3.3/3.8L
Fastener.................23N´m(200 in. lbs.)
Exhaust ManifoldÐ3.3/3.8L
Stud....................23N´m(200 in. lbs.)
Exhaust Manifold Heat ShieldÐ3.0L
Fasteners................15N´m(130 in. lbs.)
Exhaust Manifold Heat ShieldÐ3.3/3.8L
Fasteners................12N´m(105 in. lbs.)
Exhaust Manifold CrossoverÐ3.0L
Bolts.....................69N´m(51ft.lbs.)
Exhaust Manifold CrossoverÐ3.3/3.8L
Fasteners..................54N´m(40ft.lbs.)
Exhaust Manifold Flange (All)
Fastener.................28N´m(250 in. lbs.)
Heat ShieldÐMuffler
Fastener...................2N´m(23in.lbs.)
Heat ShieldÐToe Board
Fastener...................2N´m(23in.lbs.)
Insulator Mounting Bracket
on Muffler to Body
Bolts....................28N´m(250 in. lbs.)
Insulator Mounting Bracket
on Resonator to Body
Bolts....................28N´m(250 in. lbs.)
Intake Manifold Gasket Retainer
Fastener.................12N´m(105 in. lbs.)
Intake Air PlenumÐ3.0L
Bolts....................15N´m(130 in. lbs.)
Intake (Cross) ManifoldÐ3.0L
Bolts....................20N´m(174 in. lbs.)
Intake Plenum Support BracketÐ3.3/3.8L
Fastener..................54N´m(40ft.lbs.)
Intake ManifoldÐ2.4L
Fastener.................28N´m(250 in. lbs.)
Intake Manifold UpperÐ2.4L
Bolts....................28N´m(250 in. lbs.)
Intake ManifoldÐ3.3/3.8L
Fastener.................23N´m(200 in. lbs.)
Intake Manifold PlenumÐ3.3/3.8L
Bolts....................28N´m(250 in. lbs.)
Muffler Hanger Support Clamp
Fastener.................17N´m(150 in. lbs.)
11 - 18 EXHAUST SYSTEM AND INTAKE MANIFOLDNS

(4) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
(1) Position front bumper reinforcement on vehicle.
(2) Install nuts to hold reinforcement to frame
rails. Tighten nuts to 54 N´m (40 ft. lbs.) torque.
(3) Install front fascia.
REAR BUMPER FASCIA
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Hoist and support vehicle on safety stands.
(3) Remove screws holding rear fascia to rear fas-
cia brackets (Fig. 3).
(4) Remove plastic rivets holding bottom of rear
fascia to bumper reinforcement.
(5) Disengage hooks on sides of fascia from tabs in
rear fascia brackets.
(6) Remove rear fascia from vehicle.
INSTALLATION
(1) Position rear fascia on vehicle.
(2) Engage fascia tabs under liftgate.
(3) Engage hooks on sides of fascia to tabs in rear
fascia brackets.
NOTE: Verify all fascia tabs are still engaged under
the liftgate. Ensure acceptable and consistent gap
between liftgate and fascia.
(4) Install plastic rivets to hold bottom of rear fas-
cia to bumper reinforcement.
(5) Install screws holding rear fascia to rear fascia
brackets.
(6) Lower vehicle.
REAR BUMPER REINFORCEMENT
REMOVAL
(1) Remove rear bumper fascia.
(2) Support rear bumper reinforcement on a suit-
able lifting device.
(3) Mark position of nuts on frame rail extensions
to aid installation.
(4) Remove nuts holding rear bumper reinforce-
ment to frame rail extensions (Fig. 4).
(5)
Remove rear bumper reinforcement from vehicle.
INSTALLATION
(1) Position rear bumper reinforcement on vehicle.
(2) Loosely install nuts to hold rear bumper rein-
forcement to frame rail extensions (Fig. 4).
(3) Align nuts to previously made marks on frame
rail extensions. Tighten nuts to 27 N´m (20 ft. lbs.)
torque.
(4) Install rear bumper fascia.
Fig. 2 Front Bumper ReinforcementFig. 3 Rear Bumper Fascia
Fig. 4 Rear Bumper Reinforcement
13 - 2 FRAME AND BUMPERSNS
REMOVAL AND INSTALLATION (Continued)

(7) Connect lower ball joints to lower control arms.
Refer to Group 2, Suspension.
(8) Connect stabilizer bar links to ends of stabi-
lizer bar. Refer to Group 2, Suspension.
(9) Install bolts to hold anti-lock brake sensor
leads to crossmember.
(10) Install high pressure hose to pump.
(11) Connect return hose to metal tube.
(12) Tighten hose clamp at the crossmember cou-
pling.
(13) Remove pinch-off pliers.
(14) Position steering so front wheels are straight
ahead.
(15) Install steering column coupling to telescoping
steering gear shaft.
(16) Install clinch bolt to hold steering column cou-
pling to steering gear shaft.
(17) Install knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(18) Install steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(19) Connect battery negative cable.
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
crossmember on frame rails.
(2) Loosen bolts holding crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow crossmember to drop down enough to
gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lube or soap to replacement bush-
ing.(2) Insert lower half of bushing into square hole in
crossmember.
(3) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(4) Squeeze bushing halves together to ensure they
are properly mated.
(5) Lift crossmember upward to close gap between
the bushing and frame.
(6) Verify that lower bushing is fully seated into
crossmember and upper bushing.
(7) Install bolt to hold bushing and crossmember
to frame rail hand tight.
(8) Align crossmember to reference marks on
frame rails.
(9) Tighten crossmember to frame rails attaching
bolts to 163 N´m (120 ft. lbs.) torque.
SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS
Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location.
VEHICLE PREPARATION
Position the vehicle on a frame alignment rack,
refer to instructions provided with equipment being
used. Adjust the vehicle PLP heights to the specified
dimension above the work surface (datum line). Ver-
tical dimensions can be taken from the datum line to
the locations indicated were applicable. Refer to (Fig.
5), (Fig. 6), (Fig. 7), (Fig. 8), (Fig. 9), (Fig. 10) and
(Fig. 11) for proper dimensions.
NSFRAME AND BUMPERS 13 - 5
REMOVAL AND INSTALLATION (Continued)