1996 CHRYSLER VOYAGER air suspension

(13) Lower the vehicle to the ground.Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Tighten the spring to front hanger pivot bolts
to a torque of 156 N´m (115 ft. lbs.).
(15) Tighten the shock absorber mounting bolts to
a torque of 101 N´m (75 ft. lbs.).
(16) Tighten the track bar mounting bolt to a
torque of 95 N´m (70 ft. lbs.).
(17) Road test vehicle to ensure that the prema-
ture rear wheel lockup condition has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKESNS
ADJUSTMENTS (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)

(4) Remove the vertical and horizontal fasteners
from the engine side bracket. Remove the engine
mount assembly
INSTALLATION
(1) Reverse removal procedure for installation.
Tighten assembly in the following order:
a. Engine mount to rail fasteners to 68 N´m (50 ft.
lbs.).
b. The vertical engine fastener to 102 N´m (75 ft.
lbs.)
c. The horizontal fastener to 150 N´m (111 ft. lbs.).
(2) Install the purge duty solenoid and wiring har-
ness to the engine mount.
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
FRONT MOUNT
REMOVAL
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 24).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly.
(5) Remove the front mounting bracket, if neces-
sary (Fig. 24).
INSTALLATION
(1) Reverse removal procedure for installation and
tighten fasteners in this order:
a. Tighten bolts 2,3, and 4 to 108 N´m (80 ft. lbs.).
b. Tighten bolts 1 and 5 to 54 N´m (40 ft. lbs.).
(2) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.(3) Install six screws to air dam and tighten to 12
N´m (105 in. lbs.).
LEFT SIDE MOUNT
REMOVAL
(1) Raise vehicle on hoist and remove left front
wheel.
(2) Support the transmission with a transmission
jack.
(3) Remove the insulator through bolt from the
mount.
(4) Remove the transmission mount fasteners and
remove mount.
INSTALLATION
(1) Reverse removal procedure for installation.
(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.)
(3) Tighten through bolt to 75 N´m (55 ft. lbs.)
(Fig. 25).
(4) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
REMOVAL
(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.
INSTALLATION
(1) Reverse the removal procedure for installation.
Refer to (Fig. 26). Tighten through bolt to 75 N´m (55
ft. lbs.)
Fig. 23 Engine MountÐRight
Fig. 24 Engine MountingÐFront
NS3.3/3.8L ENGINE 9 - 103
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)

FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER MOUNT BUSHINGS . . . 5
FRONT CROSSMEMBER................... 3SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS.... 5
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER
The front suspension crossmember must be
installed in the design location to achieve proper
front end suspension alignment. If the crossmember
is removed without applying reference marks on the
frame rails, align the crossmember according to the
dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through a MoparTParts supplier.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to airbag clock spring can result.
(5) Remove clinch bolt holding steering column
coupling to steering gear shaft (Fig. 1).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist and support vehicle on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the crossmember cou-
pling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut hold-
ing high pressure hose to back of pump.(13) Separate high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts holding anti-lock brake sensor
leads to crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar. Refer to Group 2, Suspension.
(18) Disconnect lower ball joints from lower control
arms. Refer to Group 2, Suspension.
(19) Remove bolt holding rear engine mount to
crossmember (Fig. 2).
(20) Using paint or grease pencil, mark outline of
crossmember on frame rails to aid installation.
(21) Support crossmember on suitable lifting
device (Fig. 4).
(22) Remove bolts holding crossmember to front
frame rails (Fig. 3).
(23) Remove crossmember from vehicle (Fig. 4).
Fig. 1 Steering Coupling Boot
NSFRAME AND BUMPERS 13 - 3

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)

BINDING STICKING SEIZED
SHAKE SHUDDER VIBRATION
CONDITION POSSIBLE CAUSES CORRECTION
CATCHES, STICKS IN CERTAIN
POSITIONS OR IS DIFFICULT TO
TURN.1. Low power steering fluid level. 1. Fill power steering fluid reservoir
to specified level and perform
leakage diagnosis.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified
pressure.
3. Lack of lubrication in front
suspension lower control arm ball
joints.3. Replace lower ball joint.
4. Worn lower ball joint. 4. Replace the lower ball joint.
5. Lack of lubrication in steering
gear outer tie rod ends.5. Replace tie rod end.
6. Loose power steering pump drive
belt.6. Tighten the power steering pump
drive belt to the specified tension.
See accessory drive in service
manual.
7. Faulty power steering pump flow
control. (Verify cause using Power
Steering Pump Test Procedure.)7. Replace power steering pump.
8. Excessive friction in steering
column or intermediate shaft.8. Correct condition. (See Steering
Column Service Procedure)
9. Steering column coupler binding. 9. Realign the steering column to
eliminate the binding condition.
10. Binding lower ball joint. 10. Replace the lower ball joint.
11. Excessive friction in steering
gear.11. Replace steering gear assembly.
CONDITION POSSIBLE CAUSES CORRECTION
VIBRATION OF THE STEERING
WHEEL AND/OR DASH DURING
DRY PARK OR LOW SPEED
STEERING MANEUVERS.1. Air in the fluid of the power
steering system.1. Steering shudder can be expected
in new vehicles and vehicles with
recent steering system repairs.
Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check the inner to outer tie rod
jam nut for looseness. If loose
tighten to the specified torque.
Inspect inner tie rod for looseness at
steering gear. Inspect outer tie rod
ball for excessive wear/looseness. If
inner tie rod is loose replace steering
gear, if outer tie has excessive wear
replace tie rod end.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis)
19 - 4 STEERINGNS
DIAGNOSIS AND TESTING (Continued)

LOOSE STEERING
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE STEERING WHEEL
KICKBACK OR TOO MUCH
STEERING WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Fill power steering fluid reservoir
to the specified level. Perform
procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front
suspension crossmember.2. Check steering gear to front
suspension crossmember mounting
bolt torque. Tighten to specified
torque if found to be loose.
3. Worn, broken or loose steering
column to steering gear coupler.3. Check for worn universal joint,
broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of steering
system and repair or replace as
required. Note: Inspect steering
column with steering wheel installed
and steering column shaft
disconnected from intermediate
coupler. Verify that steering wheel
attaching nut is tightened to the
specified torque. Verify that the 4
mounting nuts for the steering
column are tightened to the specified
torque.
5. Loose lower control arm ball joint. 5. Check and or replace the ball joint
or control arm as required.
6. Loose steering knuckle to lower
ball joint stud attaching nut.6. Check attaching nut and tighten if
required to specified torque.
7. Front wheel bearings loose or
worn.7. Tighten hub nut to specified
torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10. Defective steering gear rotary
valve.10. Replace steering gear assembly.
11. Intermediate steering shaft
coupler flex joint binding.11. Replace intermediate steering
shaft/coupler.
19 - 6 STEERINGNS
DIAGNOSIS AND TESTING (Continued)