1996 CHRYSLER VOYAGER service

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Page 691 of 1938

CHRYSLER VOYAGER 1996 Service Manual POWERTRAIN
CONTROL
MODULE
BR/YL18 T41
76C2
TRANS
RANGE
SWITCH
T41
SENSE
P/N
10
SERVO CONTROL
SPEED
VEHICLE
13
4
STOP
LAMP
SWITCH
V30
18
DB/RD
213
C280
VENT
SOLENOID SOLENOIDVACUUM
56C2
V35
18
LG/RD
TN

Page 779 of 1938

CHRYSLER VOYAGER 1996 Service Manual 8W-46 MESSAGE CENTER
Component Page
A/C Heater Control..................8W-46-2, 3
ABS Warning Lamp...................8W-46-2
Airbag Control Module.................8W-46-2
Airbag Warning Lamp.........

Page 781 of 1938

CHRYSLER VOYAGER 1996 Service Manual (ST-RUN) IGNITIONFUSED
GY/BK20 G9
Z1
20
BK
14
G200
IGNITION
SWITCH
4 1
2
03
2C1
1C1
BK20Z1
G300
9
SWITCH PRESSURE
BRAKE
B
1C2
A
G9
20
GY/BK
GY/BK20 G9
PARK
BRAKE
SWITCH
C39
C38
G9
20
GY/BK
JUNCTION
BL

Page 934 of 1938

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Page 947 of 1938

Page 1051 of 1938

CHRYSLER VOYAGER 1996 Service Manual ENGINE
CONTENTS
page page
2.4L ENGINE............................ 14
3.0L ENGINE............................ 61
3.3/3.8L ENGINE........................ 93ENGINE DIAGNOSIS....................... 7
STAN

ENGINE
CONTENTS
page page
2.4L ENGINE............................ 14
3.0L ENGINE............................ 61
3.3/3.8L ENGINE........................ 93ENGINE DIAGNOSIS....................... 7
STANDARD SERVICE PROCEDURES.......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
GENERAL INFORMATION
CRANKSHAFT SPROCKET BOLT ACCESS
PLUG................................ 2
ENGINE CORE PLUGS.................... 2
ENGINE OIL SERVICE..................... 5
ENGINE OIL............................. 5
ENGINE PERFORMANCE.................. 2FORM-IN-PLACE GASKETS................. 1
HONING CYLINDER BORES................ 3
HYDROSTATIC LOCKED ENGINE............ 5
MEASURING MAIN BEARING AND
CONNECTING ROD BEARING
CLEARANCES......................... 3
REPAIR OF DAMAGED OR WORN THREADS . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets.Do not use
form-in-place gasket material unless specified.
Bead size, continuity, and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over, a continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine.MopartSilicone Rubber Adhe-
sive Sealant andMopartGasket Maker, (anaerobic)
each have different properties and cannot be used
interchangeably.
CAUTION: Silicone sealer and anaerobic sealers
each will inhibit the cure of the other and care
should be taken to keep usages separated as much
as possible.
MOPARTSILICONE RUBBER ADHESIVE
SEALANT
MopartSilicone Rubber Adhesive Sealant or
equivalent, normally black in color, is available in
three ounce tubes. Moisture in the air causes the
MopartSilicone Rubber Adhesive Sealant material
to cure. This material is normally used on flexible
metal flanges. It has a shelf life of one year and will
not properly cure if over age. Always inspect the
package for the expiration date before use.
MOPARTGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material normally red in color. The material cures in
the absence of air when squeezed between two metal-
lic surfaces. It will not cure if left in the uncovered
tube. It is normally red in color. The anaerobic mate-
rial is for use between two machined surfaces. Do not
use on flexible metal flanges.
MOPARTTORQUE CURE GASKET MAKER
MopartTorque Cure Gasket Maker is a unique
anaerobic type gasket material to be usedONLY
between the bedplate and engine block. The material
cures in the absence of air when torqued between
two metallic surfaces. It will not cure if left in the
uncovered tube. This anaerobic material is specially
NSENGINE 9 - 1

Page 1052 of 1938

CHRYSLER VOYAGER 1996 Service Manual made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets

made to seal the area between the bedplate and cyl-
inder block without disturbing the bearing clearance
or alignment of these components.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some
instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
TheMopartSilicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3 mm (0.120 in.) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop
is placed in the center of the gasket contact area.
Uncured sealant may be removed with a shop towels.
Components should be torqued in place while the
sealant is still wet to the touch (within 10 minutes).
The usage of a locating dowel is recommended during
assembly to prevent smearing of material off loca-
tion.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert the proper size
socket, extension and ratchet, when crankshaft rota-
tion is necessary.
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup
plug (Fig. 1). With the cup plug rotated, grasp firmlywith pliers or other suitable tool and remove plug
(Fig. 1).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup
plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole
with sealer. Make certain the new plug is cleaned of
all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at
least 0.5 mm (0.020 inch.) inside the lead in chamfer
(Fig. 1).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or
chain may have skipped one or two teeth. Camshaft
and crankshaft timing should be checked. Refer to
Group 9, Engine Timing belt or chain installation.
It is important that the vehicle is operating to its
optimum performance level to maintain fuel economy
and lowest vehicle emissions. If vehicle is not operat-
ing to these standards, refer to Engine Diagnosis out-
lined is this section. The following procedures can
assist in achieving the proper engine diagnosis.
(1) Test cranking amperage draw. Refer to Group
8B, Starting.
(2) Check intake manifold for vacuum leaks.
(3) Perform cylinder compression pressure test.
Refer to Engine Diagnosis, outlined in this section.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Group 8D, Ignition System.
Tighten to specifications.
Fig. 1 Core Hole Plug Removal
9 - 2 ENGINENS
GENERAL INFORMATION (Continued)

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