1996 CHRYSLER VOYAGER air conditioning

C62
POWER
DISTRIBUTION
CENTER
8587
3086A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7C6
1PTC
9A
C130
BLOCK JUNCTION
ST-RUN A21
6C2
F87
18
WT/BK
C261
POWERTRAIN
CONTROL
MODULE5V
SUPPLY
1
2
CLUTCH COMPRESSOR
A/C
G102 ES23
C3
18
DB/BK
Z1
18
BK
Z1
12
BK
64C2
CONTROL CLUTCH RELAYCOMPRESSORA/C
213
TRANSDUCER
PRESSURE
A/C
SIGNAL SWITCH PRESSUREA/C
42C2
SENSOR
GROUND
C243
C13
18
DB/ORES03
K6
18
VT/WT
K6
18
VT/WT
C18
18
DB
6C61C6
ES07
F87
18
WT/BKF87
18
BK/WT
3.3L/3.8L 2.0L
K4
18
BK/LB
ES02
ES21
ES21 FS01
BK/LB18 K4
K4
18
BK/LB
ES21
ES02
2.4L
5E69 F09
ES02
(8W-10-10)
(8W-10-29)(8W-10-8) (8W-12-13)(8W-12-2) (8W-10-16)
(8W-30-5) (8W-15-2) (8W-15-2)(8W-70-7) (8W-12-13)
(8W-70-4)
(8W-70-4)
(8W-70-5) (8W-70-5) (8W-70-6)
(8W-70-6)
(8W-70-5) (8W-12-13)
NS/GS8W-42 AIR CONDITIONING-HEATER
GAS8W - 42 - 7
GS004207J988W-3

POWER
DISTRIBUTION
CENTER
C2
73
POWERTRAIN
CONTROL
MODULERADIATOR
FAN
RELAY
CONTROL
1
2
NO. 1 FAN
RADIATOR RADIATOR
FAN
NO. 2
2 1
4
3
RELAY FAN
RADIATOR
24FUSE40A
BATT A0
C76
G102RFS2
FUSED
B (+)
FAN
RELAY
CONTROLRELAY
2
RFS1
1E40
RF3
C23
12
DG
C23
12
DG
C23
12
DGC23
12
DG
1 GROUND
ES23
Z1
14
BK
Z1
12
BKZ1
12
BK
Z1
12
BK
E40 RF32
Z1
12
BK
Z1
12
BK
A16
12
GY
MM
LG/DB14 K173
RADIATOR
OUTPUTRADIATOR
FAN
(8W-10-8)
(8W-30-5) (8W-10-15)(8W-10-8)
(8W-15-2)(8W-15-2)
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER
GASNS/GS
J988W-3GS004208

C62
POWER
DISTRIBUTION
CENTER
8587
3086A/C
COMPRESSOR
CLUTCH
RELAY
15A
FUSE
11
BATT A0
7C6
1C6
19
POWERTRAIN
CONTROL
MODULE5V
SUPPLY
CLUTCH COMPRESSOR
A/C
C3
18
DB/BK
28
CONTROL CLUTCH RELAYCOMPRESSORA/C
213
TRANSDUCER
PRESSURE
A/C
SIGNAL SWITCH PRESSUREA/C
13
SENSOR
GROUND 33
C13
20
DB/OR
K7
20
ORC18
20
DBK4
20
BK/LB
2
Z2
18
BK
Z1
16
BK
Z0
10
BK
ES01 ES02Z0
6
BK
G100
Z0
2
BK
G103
BATTERY
30
87
DIESEL
POWER
RELAY
20A
FUSE
17
BATT A0C65
ES29ES06
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
9E97
B106
C13
20
DB/OR
BS34
1(8W-10-9)
(8W-10-29)(8W-10-8)
(8W-30-38) (8W-20-3)
(8W-15-3)
(8W-15-3)(8W-30-28) (8W-10-25)(8W-10-8) (8W-10-25)(8W-10-25)
(8W-70-11)
NS/GS8W-42 AIR CONDITIONING-HEATER
DIESEL8W - 42 - 9
GS004209J988W-3

POWER
DISTRIBUTION
CENTER
6
POWERTRAIN
CONTROL
MODULE
24FUSE40A
BATT A0
C76
A16
12
GY
NO. 1 RELAY
FAN
RADIATOR
6
RADIATOR
FAN
RELAY
NO. 2
48
2662
4
NO. 3 RELAY
FAN
RADIATOR
4
312
ES07
C25
12
YL
LOW
SPEED
RADIATOR
RELAY NO. 2
CONTROLC24
20
DB/PK
CONTROL NO.1 & NO.3RADIATORSPEEDHIGH
48
ES09
1E95
B10710B106 E97ES29
C24
20
DB/PK
C137
20
YLC137
20
YL
C137
20
YL
A142
18
DG/ORA142
18
DG/ORA142
18
DG/OR
C27
12
DB/PKC27
12
DB/PK
C27
12
DB/PK
BATT A17
ES12
G102
Z1
12
BK
Z1
12
BK
Z1
12
BK
C116
12
LG/WT
DRIVER'S
SIDE
RADIATOR
FAN FANRADIATOR
SIDE
PASSENGER'S
MMDISCONNECT
FAN
RADIATOR
48
258A17
12
RD/BK
(8W-10-8)
(8W-30-37)(8W-10-15)(8W-10-8)
(8W-10-25)
(8W-15-3)
(8W-15-3)(8W-10-19)
8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER
DIESELNS/GS
J988W-3GS004210

ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose and remove radia-
tor fans. Refer to Group 7, Cooling System for proce-
dure.
(6) Remove lower radiator hose.
(7) Disconnect automatic transmission cooler lines
and plug, if equipped.
(8) Disconnect transmission shift linkage.
(9) Disconnect throttle body linkage.
(10) Disconnect engine wiring harness.
(11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(13) Hoist vehicle and remove right inner splash
shield. Remove wheels and tires.
(14) Loosen power steering belt for pump removal.
Refer to Group 7, Cooling System for procedure.
(15) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front and rear engine mount brackets
from the body.
(18) Remove bending braces and front engine
mount bracket. Remove transmission inspection
cover.
(19) Mark flexplate to torque converter and
remove torque converter bolts.
(20) Install front engine mount bracket.
(21) Lower vehicle.
(22) Remove power steering pump. Set pump
aside.
(23) Remove A/C lines at compressor and cap.
(24) Remove ground straps to body.
(25) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 and Adaptor Special Tool
8130 to be installed under vehicle (Fig. 27).
(26) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
front engine bracket and A/C compressor bracket
(Fig. 27). Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.(27) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(28) Remove engine and transmission mount bolts.
(29) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around the body.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt ten-
sion adjustment.
(8) Install A/C compressor hoses. Refer to Group
24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front and rear engine mounts. Refer to
this section for procedure.
(11) Install inner splash shield. Install wheels and
tires.
(12) Connect automatic transmission cooler lines,
and shift linkage. Refer to Group 21, Transmission
for procedures.
(13) Connect fuel line and heater hoses.
(14) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(15) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(16) Install radiator fans. Install radiator hoses.
Fill cooling system. Refer to Group 7, Cooling System
for filling procedure.
(17) Connect battery.
(18) Install air cleaner and hoses.
(19) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(20) Start engine and run until operating temper-
ature is reached.
(21) Adjust transmission linkage, if necessary.
9 - 26 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.) (Fig. 22).
Tighten through bolt to 75 N´m (55 ft. lbs.)
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
(1) Raise vehicle on hoist.
(2) Support the transmission with a transmission
jack so it will not rotate.
(3) Remove the insulator through bolt from the
mount and rear suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount.
(5) Reverse the removal procedure for installation.
Refer to (Fig. 23).
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
driveshaft assembly length. See Engine Mount
Adjustments in this section.
Check and reposition right engine mount insulator.
Adjust drive train position, if required, for the follow-
ing conditions:
²Driveshaft distress: See Group 2, Suspension
and Driveshafts.
²Any front end structural damage (after repair).
²Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7, Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
(24) Lower the vehicle.
Fig. 22 Engine MountÐLeft
Fig. 23 Engine MountÐRear
NS3.0L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

(25) Remove ground straps to body.
(26) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 24).
(27) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.
(28) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(29) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(30) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909.
(4) Remove Special tools 6910 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Group 7. Accessory
Drive Belts Section for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 2, Driveshafts for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts in this
section for procedure.
(11) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(12) Install left and right inner splash shields.
(13) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(14) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(15) Install ground straps. Connect engine and
throttle body connections and harnesses.
(16) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(17) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. Refer to
Group 7, Cooling for procedures.
(18) Install battery tray, battery and cover.
(19) Install air cleaner and hoses.
(20) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(21) Start engine and run until operating temper-
ature is reached.
(22) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air inlet resonator when removing left
head cover.
(3) When Removing left cylinder head cover,
remove dipstick tube.
(4) When removing right cylinder head cover
remove wiper unit. Refer to Wiper Unit Removal in
Group 8K.
(5) When removing right cylinder head cover,
remove accessory drive belt. Refer to Accessory Drive
Belt Removal in Group 7.
Fig. 24 Positioning Engine Cradle Support Post
MountsÐTypical
9 - 70 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
drive shaft assembly length.
Check and reposition right engine mount insulator.
See Adjustments in this section. Adjust drive train
position, if required, for the following conditions:
a. Drive shaft distress. See Group 2, Suspension
and Driveshafts.
b. Any front end structural damage (after repair).
c. Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to group 14 fuel system for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7 Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Group
7, Accessory Drive Belts located in Cooling System
for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove right and left inner
splash shields.
(15) Remove crossmember cradle plate (Fig. 27).
(16) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(17)(AWD equipped)Mark orientation and sepa-
rate propeller shaft from power transfer unit. Refer
to Group 3, Differential and Driveline for procedure.
(18) Disconnect exhaust pipe from manifold.
(19) Remove front engine mount and bracket as an
assembly.
Fig. 25 Engine MountingÐLeft
Fig. 26 Engine MountingÐRear
Fig. 27 Crossmember Cradle Plate
9 - 104 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)