1996 CHRYSLER VOYAGER gas type

(4) Remove upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifolds for proce-
dure.
(5) Remove cylinder head covers and spark plugs.
(6) Remove electrical connector from ignition coils.
(7) Using suitable socket and flex handle at crank-
shaft pulley retaining screw, turn engine so the num-
ber 1 piston is at Top Dead Center on the
compression stroke.
(8) Remove rocker arms with rocker shaft and
install a dummy shaft. The rocker arms should not
be disturbed and left on shaft.
(9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 90 to
100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
(10) Using Tool C-4682 or equivalent, compress
valve spring and remove retainer valve locks and
valve spring.
(11) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the
locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(12) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(13) Remove spark plug adapter tool.
(14) Remove dummy shaft and install rocker shaft
assembly and tighten screws to 28 N´m (250 in. lbs.).
(15) Install cylinder head covers tighten screws to
14 N´m (120 in. lbs.) and electrical connector to igni-
tion coils.
(16) Install Intake Manifold. Refer to Group 11,
Exhaust System and Intake Manifold for procedure.
(17) Connect negative cable to battery.
CYLINDER HEAD COVER
REMOVAL
NOTE: The cylinder head cover can be either an
isolated type (Fig. 32) or a non-isolated type.
FRONT CYLINDER HEAD COVER
(1) Disconnect ignition cables from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove front cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.REAR CYLINDER HEAD COVER
(1) Disconnect negative cable from battery.
(2) Remove Wiper Unit. Refer to Group 8K, Wind-
shield Wipers and Washers for procedure.
(3) Remove intake manifold upper plenum. Refer
to Group 11, Exhaust System and Intake Manifold
for procedure.
(4) Disconnect PCV hose from cylinder head cover.
(5) Remove rear cylinder head cover bolts
(6) Remove cylinder head cover and gasket.
INSTALLATION
FRONT CYLINDER HEAD COVER
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Install cylinder head cover and bolts.
(3) Tighten cylinder head cover bolts to the follow-
ing specifications:
²Non±isolatedcylinder head cover to 12 N´m
(105 in. lbs.).
²Isolatedcylinder head cover to 10 N´m (90 in.
lbs.) (Fig. 32).
(4) Connect crankcase vent hose.
(5) Connect ignition cables to spark plugs.
REAR CYLINDER HEAD COVER
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Install cylinder head cover and bolts.
(3) Tighten cylinder head cover bolts to the follow-
ing specifications:
Fig. 32 Cylinder Head CoverÐIsolated Type
NS3.3/3.8L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)

Service Tappets Available........Std., 0.025 mm
(0.001), 0.20 mm (0.008 in.),
0.762 mm (0.030 in.)
Cylinder Head
Gasket Thickness (Compressed)........1.78 mm
(0.070 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust...........45-45.5É
Runout (Max)............0.0762 mm (0.003 in.)
Width (Finish)±Intake...........1.75 - 2.25 mm
(0.069 - 0.088 in.)
Width (Finish)±Exhaust.........1.50 - 2.00 mm
(0.057 - 0.078 in.)
Valve Guides
Type..................Powdered Metal Inserts
Guide Bore Diameter...........7.975 - 8.00 mm
(0.314 - 0.315 in.)
ValvesÐIntake
Face Angle...........................44.5É
Head Diameter..............45.5 mm (1.79 in.)
Length (Overall)..........127.005 - 128.036 mm
(5.000 - 5.041 in.)
Minimum Valve Length
After Tip Grinding...................124.892
(4.916 in.)
Lift (Zero Lash)...........10.16 mm (0.400 in.)
Stem Diameter (Standard)......7.935 - 7.953 mm
(0.312 - 0.313 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem-to-Guide Clearance.......0.025 - 0.095 mm
(0.001 - 0.003 in.)
Max. Allowable (Rocking Method). . . .0.247 mm
(0.010 in.)
Valves for Service
(Oversize Stem Diameters).......Std., 0.015 mm
(0.005 in.), 0.40 mm (0.015 in.),
0.80 mm (0.030 in.)
ValvesÐExhaust
Face Angle.............................45É
Head Diameter.............37.5 mm (1.476 in.)
Length Overall..............127.825 - 128.465
(5.032 - 5.058 in.)
Minimum Valve Length
After Tip Grinding.......125.512 mm (4.941 in.)
Lift (Zero Lash)............10.16 mm (0.40 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem Diameter (Standar).......7.906 - 7.924 mm
(0.3112 - 0.3119 in.)
Stem to Guide Clearance.......0.051 - 0.175 mm
(0.002 - 0.006 in.)Max. Allowable (Rocking Method)......0.414 mm
(0.016 in.)
Valves for Service (Oversize
Stem Diameters)......Std., 0.015 mm (0.005 in.),
0.40 mm (0.015 in.), 0.80 mm (0.030 in.)
Valve Springs
Free Length (Approx.).......48.5 mm (1.909 in.)
Wire Diameter.............4.75 mm (0.187 in.)
Number of Coils.........................6.8
Spring Tension (Valve Closed).......95-100lbs.
@ 1.57 in.
Spring Tension (Valve Open).......207 - 229 lbs.
@ 1.169 in.
Installed Height (Spring
Seat to Bottom of Retainer)......41.2 - 42.7 mm
(1.622 - 1.681 in.)
Oil Pump
Pump Type...............Rotary Full Pressure
Clearance Over Rotors
(Inner & Outer Max.)........0.10 mm (0.004 in.)
Cover Out-of-Flat (Max.).....0.025 mm (0.001 in.)
Inner Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Diameter (Min.) .79.95 mm (3.148 in.)
Outer Rotor Clearance.......0.39 mm (0.015 in.)
Tip Clearance Between Rotors (Max.). . . .0.20 mm
(0.008 in.)
Oil Pressure
Minimum Pressure at Idle (Engine
Fully Warmed Up)*...........34.47 kPa (5 psi)
At 3000 rpm.........205 - 551 kPa (30 - 80 psi)
Oil Filter Bypass Valve Setting......62-103kPa
(9 - 15 psi)
Oil Filter Type.....................Full Flow
Oil Pressure Switch Actuating
Pressure (Min.)...........14-28kPa(2 - 4 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
NS3.3/3.8L ENGINE 9 - 125
SPECIFICATIONS (Continued)

ENGINE OIL CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist vehicle. Refer to Hoisting and Jacking
Recommendations.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan (Fig. 5). Inspect drain plug
threads for stretching or other damage. Replace
drain plug if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL
ENGINE OIL QUALITY
Use only oils conforming to API (American Petro-
leum Institute) quality SG/CD, or CCMC G4. Use
only Diesel engine oil meeting standardMIL-2104C
or API service classificationSG/CD or CCMM PD1.
OIL VISCOSITY
Grade 15W-40 is recommended for temperatures
between +35ÉC to ±10ÉC (95ÉF to 14ÉF). Low viscosity
oils must have the proper API quality or the CCMC
G5 designation. Low viscosity oils are preferred when
minimum temperatures consistently fall below ±12ÉC
(10ÉF).
ENGINE OIL FILTER CHANGE
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the oil filter base (Fig. 6).
(4) When filter separates from base, tip gasket end
upward to minimize oil spill. Remove filter from vehi-
cle.
(5) With a cloth, wipe clean the gasket sealing sur-
face of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto the base. When gasket
makes contact with sealing surface, hand tighten fil-
ter one full turn, do not over tighten.
Fig. 5 Oil Drain Plug
Fig. 6 Oil Filter
9 - 48 ENGINENS/GS
SERVICE PROCEDURES (Continued)

(3) If internal diameter of original bearing is being
checked and figures are not within specifications,
new bearings must be used.
(4) Check crankshaft main bearing journals to
bearing clearances. Clearances of main bearings is
.03 to .088mm (.0011 to .0035 in.).
OIL PAN
Remove all gasket material from cylinder block. Be
careful not gouge pan sealing surface.
CYLINDER LINER
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with dail bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 inch) maximum
and cylinder bore taper is 0.100 mm (0.0039 inch)
maximum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 79). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm ( 3/8 inch.) up from bottom of bore.
SPECIFICATIONS
2.5L VM DIESEL
DESCRIPTION...........SPECIFICATIONS
Type ......................425CLIEE (36B)
Number of Cylinder......................4
Bore..............................92mm
Stroke............................94mm
Capacity.......................2499.5 cm3
Injection Order.....................1-3-4-2
Compression Ratio...............21:1 (60.5)
Crankshaft
Front Journal Diameter....................
Nominal.................62.985±63.000 mm
±0.25....................62.735±62.750 mm
±0.125...................62.860±62.875 mm
Front Bearing Diameter....................
Nominal.................63.043±63.088 mm
±0.25....................62.793±62.838 mm
±0.125...................62.918±62.963 mm
Clearance Between Journal and Bearing:
0.043±0.103 mm..........................
Center Journal Diameter...................
Fig. 77 Piston, Connecting Rod and Pin
Fig. 78 Bearing Clearance
Fig. 79 Liner Inspection
9 - 78 ENGINENS/GS
CLEANING AND INSPECTION (Continued)

DESCRIPTION...........SPECIFICATIONS
Nominal.................63.005±63.020 mm
±0.25....................62.755±62.770 mm
±0.125...................62.880±62.895 mm
Center Bearing Diameter...................
Nominal.................63.050±63.093 mm
±0.25....................62.800±62.843 mm
±0.125...................62.925±62.968 mm
Clearance Between Journal and Bearing:
0.030±0.088 mm..........................
Rear Journal Diameter.....................
Nominal.................79.980±80.000 mm
±0.25....................79.730±79.750 mm
±0.125...................79.855±79.875 mm
Rear Bearing Diameter.....................
Nominal.................80.045±80.070 mm
±0.25....................79.795±79.820 mm
±0.125...................79.920±79.945 mm
Clearance Between Journal and Bearing:
0.045±0.090 mm (Wear Limit: 0.200 mm).......
Connecting Rod Journal....................
Nominal.................53.940±53.955 mm
±0.25....................53.690±53.705 mm
±0.125...................53.815±53.830 mm
Connecting Rod Bearing....................
Nominal.................53.977±54.016 mm
±0.25....................53.727±53.766 mm
±0.125...................53.852±53.891 mm
Clearance Between Journal and Bearing:
0.022±0.076 mm (Wear Limit: 0.200 mm).......
Crankshaft End Play
End Play.....................0.08±0.21 mm
Adjustment.................Thrust Washers
Thrust Washers Available........2.31±2.36 mm
Thrust Washers Available........2.41±2.46 mm
Thrust Washers Available........2.51±2.56 mm
Main Bearing Carriers
Front....................67.025±67.050 mm
Center...................66.670±66.690 mm
Rear....................85.985±86.005 mm
Liners
Internal Diameter..........92.000±92.010 mm
Protrusion....................0.01±0.06 mm
Adjustment.........................Shims
Available Shims:...................0.15 mm
Available Shims:...................0.17 mm
Available Shims:...................0.20 mm
Available Shims:...................0.23 mm
Available Shims:...................0.25 mm
Cylinder Head
Minimum Thickness..........89.95±90.05 mm
Gasket.............................Steel
Gasket thickness:.......1.4260.1 mm 0 Holes
Gasket thickness:.......1.6260.1 mm 1 HolesDESCRIPTION...........SPECIFICATIONS
Gasket thickness:.......1.5260.1 mm 2 Holes
End Plates
Height.....................89.02±90.00 mm
Connecting Rods
Weight (Without the crank
bearing)..................1129±1195 grams
Small End Bearing Internal Diameter
Minimum.......................30.035 mm
Maximum......................30.050 mm
Crankshaft Bearings Standard Internal
Diameter.................53.997±54.016 mm
Pistons
Skirt Diameter............91.935±91.945 mm
(Measured at approximately 15 mm above the
bottom of the skirt)
Piston Clearance.............0.055±0.075 mm
Top of Piston to Cylinder Head....0.80±0.89 mm
Piston Protrusion.....0.53±0.62 mm Fit Gasket
(1.42), 0 Holes
Piston Protrusion.....0.73±0.82 mm Fit Gasket
(1.62), 1 Hole
Piston Protrusion.....0.63±0.72 mm Fit Gasket
(1.52), 2 Holes
Piston Pins
Type .........................Full Floating
Pin Diameter..............29.990±29.996 mm
Clearance..................0.004±0.014 mm
Piston Rings (Clearance in Groove)
Top .......................0.080±0.130 mm
Second.....................0.070±0.102 mm
Oil Control.................0.040±0.072 mm
Piston Rings (Fitted Gap)
Top .........................0.25±0.50 mm
Second......................0.20±0.35 mm
Oil Control...................0.25±0.58 mm
Camshaft
Journal Diameter Front.....53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Journal Diameter Center....53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Journal Diameter Rear......53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Tappets
Outside Diameter..........22.195±22.212 mm
Rocker Gear
Shaft Diameter.............21.979±22.00 mm
Bushing internal diameter . . . 22.020±22.041 mm
Assembly Clearance..........0.020±0.062 mm
Valves (Intake)
Opens........................26ÉB.T.D.C.
Closes........................58ÉA.B.D.C.
Valves (Exhaust)
Opens........................64ÉB.B.D.C.
Closes........................38ÉA.T.D.C.
NS/GSENGINE 9 - 79
SPECIFICATIONS (Continued)

CAUTION: When servicing, care must be exercised
not to dent or bend the bellows of the flex-joint.
Should this occur, the flex-joint will eventually fail
and require the catalytic converter be replaced.
DESCRIPTION AND OPERATION
INTAKE/EXHAUST MANIFOLDÐ2.4L ENGINE
The intake manifold is a tuned two-piece alumi-
num casting with individual primary runners leading
from a plenum to the cylinders. The manifold is
designed to boost torque which is desired for excel-
lent engine response and usable power output.
The exhaust manifold is made of nodular cast iron
for strength and high temperatures.
INTAKE/EXHAUST MANIFOLDÐ3.0L ENGINE
The aluminum alloy manifold is a cross type with
long runners to improve air flow. The runners,
attaching below at the cylinder head, also attach
above and support an air plenum. The air plenum
chamber absorbs air pulsations created during the
suction phase of each cylinder.Both exhaust manifolds are a log style made of
ductile cast iron. Exhaust gasses, collected from the
front cylinder bank, leave the front manifold through
an end outlet and are fed through an upper crossover
tube to the rear manifold. The collected exhaust from
both manifolds are combined at the exhaust outlet, to
the exhaust pipe.
INTAKE/EXHAUST MANIFOLDÐ3.3/3.8L ENGINES
The intake manifold is a tuned two-piece semi-per-
manent mold aluminum casting with individual pri-
mary runners leading from a plenum to the
cylinders. The manifold is designed to boost torque in
the 3600 rpm range and contributes to the engine's
broad, flat torque curve, which was desired for excel-
lent engine tractability, response and usable power
output.
The intake manifold is also cored with upper level
EGR passages for balanced cylinder to cylinder EGR
distribution.
The exhaust manifolds are log type with a cross-
over and are attached directly to the cylinder heads.
They are made from nodular cast iron.
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST
NOISE (UNDER HOOD)1. Exhaust manifold cracked or broken. 1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace gasket.
3. EGR Valve to manifold gasket leakage. 3. Tighten fasteners or replace gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace gasket.
5. EGR tube to manifold tube leakage. 5. Tighten tube nut.
6. Exhaust flex-joint to manifold leak. 6. Tighten joint fasteners and/or replace
gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter assembly.
8. Pipe and shell noise from front exhaust
pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST
NOISE1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler assembly
or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with catalytic
converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Remove restriction, if possible, or
replace as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper operation.
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
GENERAL INFORMATION (Continued)

GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
(Methyl Tertiary Butyl Ether) and ETBE (Ethyl Ter-
tiary Butyl Ether). Oxygenates are required in some
areas of the country during winter months to reduce
carbon monoxide emissions. The type and amount of
oxygenate used in the blend is important.
The following are generally used in gasoline
blends:
Ethanol- (Ethyl or Grain Alcohol) properly
blended, is used as a mixture of 10 percent ethanol
and 90 percent gasoline. Gasoline blended with etha-
nol may be used in your vehicle.
MTBE/ETBE- Gasoline and MTBE (Methyl Ter-
tiary Butyl Ether) blends are a mixture of unleaded
gasoline and up to 15 percent MTBE. Gasoline and
ETBE (Ethyl Tertiary Butyl Ether) are blends of gas-
oline and up to 17 percent ETBE. Gasoline blended
with MTBE or ETBE may be used in your vehicle.
Methanol- Methanol (Methyl or Wood Alcohol) is
used in a variety of concentrations blended with
unleaded gasoline. You may encounter fuels contain-
ing 3 percent or more methanol along with other
alcohols called cosolvents.
DO NOT USE GASOLINES CONTAINING
METHANOL.
Use of methanol/gasoline blends may result in
starting and driveability problems and damage criti-
cal fuel system components.
Problems that are the result of using methanol/
gasoline blends are not the responsibility of Chrysler
Corporation and may not be covered by the vehicle
warranty.
Reformulated Gasoline
Many areas of the country are requiring the use of
cleaner-burning fuel referred to asReformulated
Gasoline. Reformulated gasolines are specially
blended to reduce vehicle emissions and improve air
quality.
Chrysler Corporation strongly supports the use of
reformulated gasolines whenever available. Although
your vehicle was designed to provide optimum perfor-
mance and lowest emissions operating on high qual-
ity unleaded gasoline, it will perform equally well
and produce even lower emissions when operating on
reformulated gasoline.
Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents of similar ingredients that can be harmful to
fuel system gasket and diaphragm materials.
E-85 GENERAL INFORMATION
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
tion only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel etha-
nol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
FUEL REQUIREMENTS
Your vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recom-
mended that
²you do not switch when the fuel gauge indicates
less than 1/4 full
²you do not add less than 5 gallons when refuel-
ing
²you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in driv-
ability during warm up.
NOTE: When the ambient temperature is above
90ÉF, you may experience hard starting and rough
idle following start up even if the above recommen-
dations are followed.
STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0ÉF. In
the range of 0ÉF to 32ÉF, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in drivability (sags and/or hesita-
tions) until the engine is fully warmed up.
14 - 2 FUEL SYSTEMNS
GENERAL INFORMATION (Continued)

hydrocarbons. Vapors from the fuel tank are collected
in a charcoal filled canister. The vapors are held in
the canister until the engine is operating. When the
engine is running, the vapors are drawn through the
intake manifold into the combustion chambers.
PRESSURE-VACUUM FILLER CAP
The loss of any fuel or vapor out of the filler neck
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum
release for all gas caps is between 0.97 and 2.0 kPa
(0.14 and 0.29 psi). The cap must be replaced by a
similar unit if replacement is necessary.
WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with
plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 4).
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 4). When the fuel tube
enters the fitting, the retainer locks the shoulder of
the nipple in place and the O-rings seal the tube.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.The fuel system operates at approximately 338 kPa
(49 psi), 3.3L uses approximately 379 kPa (55 psi).
Check fuel system pressure at the test port on the
fuel rail (Fig. 5) or (Fig. 6).
Fig. 4 Plastic Quick-Connect Fittings
Fig. 5 Fuel Pressure Test PortÐ2.4L
14 - 6 FUEL SYSTEMNS
DESCRIPTION AND OPERATION (Continued)