1996 CHRYSLER VOYAGER engine oil

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

(6) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold (Fig. 7).
(7) Remove vacuum lines for power brake booster
and speed control vacuum reservoir at upper intake
manifold fittings (Fig. 8).
(8) Remove throttle cable and speed control cable
(if equipped) from throttle lever (Fig. 9).
(9) Remove throttle cables from bracket by com-
pressing retaining tabs.
(10) Remove two top bolts from intake manifold to
rear support bracket and spacer (Fig. 10).
(11) Remove upper bolt from intake manifold to
front support bracket (Fig. 11).
(12) Remove dipstick.
(13) Remove dipstick tube.
CAUTION: Moving the dipstick tube will cause dam-
age to the sealer, causing an oil leak. Dipstick tube
must be sealed at cylinder block.
(14) Remove upper intake manifold bolts. Remove
upper intake manifold.CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
Fig. 6 Throttle Body Electrical Connectors
Fig. 7 Vacuum Line Connections
Fig. 8 Vacuum Fitting at Rear of Upper Intake
Manifold
Fig. 9 Throttle Cable Attachment to Throttle Body
Fig. 10 Intake Manifold Rear Support Bracket
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)

(2) Tighten intake manifold fasteners in the fol-
lowing sequence (Fig. 16). Torque to 23 N´m (200 in.
lbs.). Repeat this procedure until all bolts are at
specified torque.
(3) Install intake manifold center support bracket
bolts (Y bracket):
²Fastener to block 54 N´m (40 ft. lbs.)
²Fastener to intake 28 N´m (250 in. lbs.)
(4) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in Group 14, Fuel Deliv-
ery.Push the fitting onto the chassis tube until it
clicks into place. Pull on the fitting to ensure com-
plete insertion.
(5) Reverse removal procedures 2 through 12 for
installation.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(6) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
EXHAUST MANIFOLDÐ2.4L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold at the flex-joint.
(2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 17).
(3) Remove the bolts attaching the manifold to the
cylinder head. Remove manifold (Fig. 17).
(4) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Install exhaust manifold with a new gasket
and tighten attaching nuts in the order shown in
(Fig. 17) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten bolt to 28 N´m (250 in. lbs.).
(3) Connect heated oxygen sensor lead (Fig. 17).
INTAKE MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. See Cooling System, Group 7.
(3) Remove air inlet resonator to throttle body
hose.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 18).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 19).
(6) Remove vacuum hose harness from throttle
body.
(7) Remove PCV and Brake booster hoses from
Air Intake Plenum.
(8) Remove Ignition Coil from Intake Plenum
(Fig. 20).
(9) Remove wiring connectors from coolant temper-
ature sensor (Fig. 21).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hose from fuel rail (Fig. 21).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 17 Exhaust Manifold Attaching PointsÐ2.4L
Engine
Fig. 18 Throttle Cable Attachment
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(12) Remove fasteners from Air Intake Plenum to
Intake Manifold (Fig. 22).(13) Remove Air Intake Plenum (Fig. 23).
(14) Cover intake manifold with suitable cover
when servicing (Fig. 24).
(15) Disconnect Fuel Injector wiring harness from
engine wiring harness.
Fig. 19 Electrical and Vacuum Connections to
Throttle Body
Fig. 20 Ignition Coil Removal
Fig. 21 Coolant Temperature Sensor Electrical
Connections
Fig. 22 Air Intake Plenum to Intake Manifold
Attaching Bolts
Fig. 23 Removing Air Intake Plenum
Fig. 24 Vacuum Connections for Fuel Rail and Fuel
Pressure Regulator
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)

(16) Remove fuel rail attaching bolts and lift fuel
rail assembly from intake manifold.
(17) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe.
(18) Remove nut and washer assemblies and
remove intake manifold (Fig. 25).
(19) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Position new intake manifold gaskets on cylin-
der head and install intake (cross) manifold.
(2) Install nuts and washers and tighten in sev-
eral steps in order shown in (Fig. 26) to 20 N´m (174
in. lbs.).
(3) Make sure the injector holes are clean and all
plugs have been removed.
(4) Lube injector O-ring with a drop of clean
engine oil to ease installation.
(5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(6) Install the fuel rail attaching bolts and torque
to 13 N´m (115 in. lbs.).(7) Install fuel supply and the vacuum crossover
tube hold-down bolt and torque to 10 N´m (95 in.
lbs.).
(8) Remove covering from lower intake manifold
and clean surface.
(9) Place intake manifold gasketswith beaded
sealant side upon lower manifold. Put air intake in
place. Install attaching fasteners and tighten in sev-
eral steps in sequence shown (Fig. 27) to 13 N´m (115
in. lbs.).
Fig. 25 Intake and Exhaust Manifolds Ð 3.0L Engine
Fig. 26 Fastener Tightening Sequence for Intake
(Cross) Manifold
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(10) Disconnect MAP Sensor electrical connection
(Fig. 34).
(11) Remove EGR tube flange from intake ple-
num.
(12) Remove vacuum harness connectors from
intake plenum (Fig. 34).
(13) Remove cylinder head to intake plenum strut
(Fig. 35)
(14) Remove the engine mounted ground strap.
(15) Remove the fuel hose quick connect fitting
from the fuel line by using an open end wrench push-
ing in on the plastic ring located on the end of the
fittings. Gently pull the fitting from the fuel line
(Fig. 36).
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE DUR-
ING REMOVAL.
(16) Remove direct ignition system (DIS) coils and
generator bracket to intake manifold bolt (Fig. 37).(17) Remove bolts from generator to intake mani-
fold bracket. Loosen top generator mounting bolt,
and move bracket up so intake manifold can clear
mounting studs (Fig. 38).
(18) Remove intake manifold bolts and remove the
manifold (Fig. 38).
(19) Cover intake manifold with suitable cover
when servicing (Fig. 39).
(20) Remove fuel tube retainer bracket screw and
fuel rail attaching bolts (Fig. 39). Spread the retainer
bracket to allow fuel tube removal clearance.
(21) Disconnect cam sensor and coolant tempera-
ture sensor (Fig. 40).
(22) Remove fuel injector wiring clip from intake
manifold water tube.
(23) Remove fuel rail. Be careful not to damage
the rubber injector O-rings upon removal from their
ports (Fig. 41).
(24) Remove upper radiator hose, bypass hose and
rear intake manifold hose (Fig. 42).
Fig. 34 Vacuum and Electrical Connections to Intake
Manifold
Fig. 35 Intake Manifold Plenum Support Bracket
Fig. 36 Quick Connect Fuel Fitting to Fuel Line
Fig. 37 Ignition Coils
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13
REMOVAL AND INSTALLATION (Continued)

(5) Make sure the injector holes are clean and all
plugs have been removed.
(6) Lube injector O-ring with a drop of clean
engine oil to ease installation.(7) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports (Fig. 41).
(8) Install the fuel rail attaching bolts and torque
to 22 N´m (200 in. lbs.) (Fig. 39).
(9) Install fuel tube retaining bracket screw and
torque to 4 N´m (35 in. lbs.) (Fig. 39).
(10) Connect cam sensor and coolant temperature
sensor (Fig. 40).
(11) Remove covering on lower intake manifold
and clean surface.
(12) Place the new intake manifold gasket on
lower manifold. Put upper manifold into place and
install bolts and nuts finger tight.
NOTE: At no time should the studs be replaced
with a bolt and washer.
(13) Install the generator bracket to intake mani-
fold bolt and the cylinder head to intake manifold
strut bolts. (Do not torque.)
(14) Torque intake manifold bolts to 28 N´m (250
in. lbs.) following torque sequence in (Fig. 38).
(15) Torque generator bracket to intake manifold
bolt to 54 N´m (40 ft. lbs.).
(16) Torque the cylinder head to intake manifold
strut bolts to 54 N´m (40 ft. lbs.) (Fig. 35).
(17) Connect ground strap and MAP sensor electri-
cal connectors.
(18) Connect vacuum harness to intake plenum
(Fig. 34).
(19) Using a new gasket, connect the EGR tube
flange to the intake manifold and torque to 22 N´m
(200 in. lbs.).
(20) Clip wiring harness into the hole in the throt-
tle cable bracket.
(21) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor (Fig. 33).
(22) Connect vacuum harness to throttle body (Fig.
33).
(23) Install the direct ignition system (DIS) coils.
Torque fasteners to 12 N´m (105 in. lbs.) (Fig. 37).
(24) Lubricate the end of the chassis fuel tube
with 30 wt. oil. Connect fuel supply hose to chassis
fuel tube assembly. Pull back on the quick connect
fitting to ensure complete insertion (Fig. 36). (Refer
to Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems).
(25) Install throttle cable. Refer to Group 14 Fuel
System for procedure.
(26) Connect fuel injector wiring harness.
(27) Install air cleaner and hose assembly.
(28) Connect negative battery cable. Fill Cooling
System. See Cooling System, Group 7.
(29) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 42 Intake Manifold Removal and Installation
Fig. 43 Intake Manifold Gasket
Fig. 44 Intake Manifold Gasket Sealing
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15
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