1996 CHRYSLER VOYAGER battery replacement

70É using angle torque tool. Then rotate the bolts an
additional 70É following tightening sequence.
(10) Then, tighten the 14mm bolts with special
tool VM-1018 in the following manner:
(11) Side bolts (M1-M2): Tighten M1 bolts to 30
N´m, then rotate them 85É (65). Tighten M2 bolts to
30 N´m, then rotate them 85É (65).
(12)2nd Phase:After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(13) Central bolts A-L: Starting from bolt A,
slacken and retorque it immediately to 30 N´m + 65É.
Rotate the bolt an additional 65É. Then proceed in
the same way, bolt by bolt, following alphabetical
order, as indicated.
(14) Side bolts M1-M2:Without slackening,
torque bolts M1 then bolts M2 to 90 N´m (66 ft. lbs.).
(15) Tighten intake nuts to 30 N´m (22 ft. lbs.) and
exhaust manifolds nuts to 30 N´m (22 ft. lbs.) speci-
fied torque after completing Phase 2.
(16) If the engine cylinder head is to be replaced
and the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(17) Tighten oil feed lines for rocker arm assem-
blies and oil pressure switch to 13 N´m (112 in. lbs.).
(18) Install push rods and rocker arm assemblies,
tighten nut to 29.4 N´m (264 in. lbs.).(19) Install fuel injectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) Install valve cover, tighten nuts to 14.7 N´m
(132 in. lbs.).
(21) Connect crankcase breather hose.
(22) Connect the injector sensor wire connector,
and the glow plug connectors.
(23) Install oil feed line, tighten banjo bolts to 12.7
N´m (108 in. lbs), and oil drain line to turbo.
(24) Install water manifold tighten bolts to 12 N´m
(106 in. lbs.).
(25) Install exhaust pipe to turbo elbow, tighten
bolts to 28 N´m (250 in. lbs.).
(26) Install the support strut from block to turbo-
charger exhaust elbow.
(27) Install EGR tube to EGR valve, tighten bolts
to 26 N´m (19 ft. lbs.).
(28) Install intercooler hoses at intake manifold.
(29) Install coolant pressure bottle and hoses.
(30) Install wiper module. Refer to Group 8K,
Windshield Wiper Unit Installation for procedure.
(31) Install intercooler hose at turbocharger tube.
(32) Install fuel injector lines from the pump to
injectors, tighten nuts to 17.6 N´m (156. lbs.).
(33) Connect the upper radiator hose.
(34) Connect negative cable to battery.
(35) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GSENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

REMOVAL AND INSTALLATION
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
(1) Raise vehicle on hoist and apply penetrating
oil to clamp bolts and nuts of component being
removed.
(2) Loosen clamps and supports (Fig. 5) and (Fig.
4) from exhaust system to permit alignment of parts
during assembly.
(3) When removing tailpipe, raise rear of vehicle
to relieve body weight from rear springs to provide
clearance between pipe and rear axle parts.
(4) Clean ends of pipes or muffler to assure mat-
ing of all parts. Discard broken or worn insulators,
rusted clamps, supports and attaching parts.When
replacement is required on any component of
the exhaust system. It is important that origi-nal equipment parts (or their equivalent) be
used;
²To insure proper alignment with other parts in
the system.
²Provide acceptable exhaust noise levels and does
not change exhaust system back pressure that could
effect emissions and performance.
INSTALLATION
(1) Assemble pipes, muffler support and clamp
loosely to permit alignment of all parts.
(2) Beginning at front of system, align and clamp
each component to maintain position and proper
clearance with underbody parts.
(3) Tighten the clamp and support to the proper
torques and clearances (Fig. 4).
UPPER INTAKE MANIFOLDÐ2.4L ENGINE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect air intake tube and resonator box
from throttle body and remove.
(3) Remove connector from throttle position sensor
(Fig. 6).
(4) Remove connector from idle air control motor
(Fig. 6).
(5) Remove connector from MAP sensor (Fig. 11).
Fig. 4 Exhaust System Components
Fig. 5 Band Clamp
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLDNS

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

(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)

A defective fuel injection pump, defective fuel tim-
ing solenoid or misadjusted mechanical pump timing
can cause starting problems or prevent the engine
from revving up. It can also cause:
²Engine surge at idle
²Rough idle (warm engine)
²Low power
²Excessive fuel consumption
²Poor performance
²Low power
²Black smoke from the exhaust
²Blue or white fog like exhaust
²Incorrect idle or maximum speed
The electronically controlled fuel pump has no
mechanical governor like older mechanically con-
trolled fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fastening the wiring
pigtail to the side of the pump.The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOW±PRESSURE LINES
Restricted or Plugged supply lines or fuel filter can
cause a timing fault that will cause the PCM to oper-
ate the engine in a ªLimp Homeº mode. See the
introduction of the Fuel Injection System in this
group for more information on the Limp Home mode.
Fuel supply line restrictions can cause starting prob-
lems and prevent the engine from revving up. The
starting problems include; low power and blue or
white fog like exhaust. Test all fuel supply lines for
restrictions or blockage. Flush or replace as neces-
sary. Bleed the fuel system of air once a fuel supply
line has been replaced. Refer to the Air Bleed Proce-
dure section of this group for procedures.
HIGH±PRESSURE LINES
Restricted (kinked or bent) high±pressure lines can
cause starting problems, poor engine performance
and black smoke from exhaust.
Examine all high±pressure lines for any damage.
Each radius on each high±pressure line must be
smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high±pres-
sure fuel lines with the correct replacement line.
CAUTION: The high±pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
FUEL SHUTDOWN SOLENOID TEST
Since diesel fuel injection does not use spark plugs
to start combustion, the only way to stop the engine
is to cut off the fuel supply. This is done with the
Fuel Shutdown Solenoid. If the engine cranks, but
refuses to start, it may be caused by a defective fuel
shutdown solenoid.
The fuel shutdown solenoid is not controlled
or operated by the PCM.Voltage to operate the
solenoid is supplied from the ignition (key) switch.
NOTE: Although the fuel shutdown solenoid is not
operated by the PCM, if the Fuel Shutdown Solenoid
has been disconnected, and the key turned on, the
PCM will sense that the solenoid is not in the circuit,
and will switch to a ªLimp Homeº mode. After recon-
necting the solenoid, the PCM will have to be reset
by clearing the codes with the DRBIII scan tool, or
disconnecting the vehicle's battery for several min-
utes. The DRBIII scan tool is the preferred method
for resetting the PCM. Refer to the 1998 GS 2.5L Die-
sel Powertrain Diagnostic Manual for procedure.
The fuel shutdown (shut±off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
±pressure fuel injection pump. The solenoid is
mounted to the rear of the injection pump (Fig. 23).
The solenoid controls starting and stopping of the
engine regardless of the position of the accelerator
pedal. When the ignition (key) switch is OFF, the sole-
noid is shut off and fuel flow is not allowed to the fuel
injection pump. When the key is placed in the ON or
Fig. 23 Fuel Shutdown Solenoid Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 13
DIAGNOSIS AND TESTING (Continued)

HIGH-PRESSURE LINES
All high±pressure fuel lines are of the same length
and inside diameter. Correct high±pressure fuel line
usage and installation is critical to smooth engine
operation.
CAUTION: The high±pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Remove the necessary clamps (Fig. 58) holding
the lines to the engine.
(3) Clean the area around each fuel line connec-
tion. Disconnect each line at the top of each fuel
injector (Fig. 59).
(4) Disconnect each high±pressure line fitting at
each fuel injection pump delivery valve.
(5) Very carefully remove each line from the
engine. Note the position (firing order) of each line
while removing.Do not bend the line while
removing.
CAUTION: Be sure that the high±pressure fuel lines
are installed in the same order that they were
removed. Prevent the injection pump delivery valve
holders (Fig. 58) from turning when removing or
installing high±pressure lines from injection pump.
INSTALLATION
(1) Carefully position each high±pressure fuel line
to the fuel injector and fuel injection pump delivery
valve holder in the correct firing order. Also position
each line in the correct line holder.
(2) Loosely install the line clamp/holder bolts.
(3) Tighten each line at the delivery valve to 30
N´m (22 ft. lbs.) torque.
(4) Tighten each line at the fuel injector to 30 N´m
(22 ft. lbs.) torque.
Fig. 57 Fuel Reservoir Module RemovalFig. 58 Fuel Lines and Clamps/Holders
Fig. 59 Fuel Lines at Fuel Injectors
14 - 26 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF PLUS 3 Type 7176 auto-
matic transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. Thispurges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with Mopar ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopar ATF PLUS 3 (Type 7176)
automatic transmission fluid.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
(7) Check the cooler for debris on the external sur-
faces. Clean as necessary.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRBIII scan tool.
This program allows the electronic transaxle sys-
tem to recalibrate itself. This will provide the best
possible transaxle operation. The quick learn proce-
dure should be performed if any of the following pro-
cedures are performed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid Pack Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
21 - 82 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

INSTALLATION
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CABLESÐRHD VEHICLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.(3) Disconnect gearshift cable ends from transaxle
shift levers (Fig. 16) (Fig. 17).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
(4) Remove cable to bracket retaining clips at tran-
saxle (Fig. 18).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(5) Pull cables up out of engine mount bracket.
(6) Remove gearshift knob and boot. Refer to Knob
and Boot Removal in this section.
(7) Remove console screws (Fig. 19).
(8) Remove cable retaining clips at shifter (Fig. 20)
(Fig. 21).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation. Clips must be
installed to span the slotted holes.
(9) Disconnect shift cables from shifter. Pry with
equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.
(10) Lift vehicle on hoist. Cut gearshift cable tie
strap at floor pan with diagonal cutters.
(11) Remove shift cables from vehicle by grasping
cables and grommets one at a time and tugging down
through floor pan holes (Fig. 22).
INSTALLATION
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
NOTE: High temperature tie straps must be used
when replacing cable(s). Locate the new tie strap at
the white band on the crossover cable and cinch
cables tightly together.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shifter knob and boot. refer to Shifter
Knob And Boot Removal procedure in this section.
(2) Remove console assembly. Refer to Console
Removal procedure in this section.
Fig. 13 Selector Cable Clip
Fig. 14 Crossover Cable Clip
NS/GSA±598 MANUAL TRANSAXLE 21 - 7
REMOVAL AND INSTALLATION (Continued)