1996 CHRYSLER VOYAGER sensor

(5) Drain cooling system. Refer to Group 7, Cool-
ing System for procedure.
(6) Remove heater, and upper radiator hoses at
intake manifold.
(7) Disconnect coolant temperature sensor (Fig.
14).
(8) Remove the accessory drive belt. Refer to
Accessory Drive belt Removal and Installation in
Group 7, Cooling System for procedure.
(9) Remove fasteners attaching generator bracket
to cylinder head, and block.
(10) Remove intake manifold center support
bracket bolts (Y bracket) (Fig. 15)
(11) Disconnect fuel injector harness.(12) Remove lower intake manifold fasteners (Fig.
16). Remove the manifold from engine.
(13) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
If the following items were removed, install and
torque to:
²Fuel Rail Bolts 22 N´m (200 in. lbs.)
²Engine Outlet Connector Bolts 28 N´m (250 in.
lbs.)
²Coolant Temperature Sensor 7 N´m (60 in. lbs.)
²Intake Air Temperature Sensor 28 N´m (250 in.
lbs.)
(1) Using a new intake gasket, position intake
manifold on the engine and install retaining bolts.
Fig. 13 Fuel Line Quick Disconnect
Fig. 14 Coolant Temperature SensorÐ2.4L
Fig. 15 Intake Manifold Center Support Bracket
Fig. 16 Intake Manifold Fasteners
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
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)

(10) Connect fuel line to fuel rail (Fig. 21). Torque
hose clamps to 1 N´m (10 in. lbs.).
(11) Connect vacuum harness to air intake ple-
num.
(12) Connect and coolant temperature sensor elec-
trical connector to sensor (Fig. 21).
(13) Connect PCV and brake booster supply hose
to intake plenum.
(14) Connect automatic idle speed (AIS) motor
and throttle position sensor (TPS) electrical connec-
tors (Fig. 19).
(15) Connect vacuum vapor harness to throttle
body (Fig. 19).
(16) Install throttle cable and transaxle kickdown
linkage (Fig. 18).
(17) Install air inlet resonator hose assembly to
throttle body.
(18) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple.
(19) Fill cooling system. Refer to Filling the Cool-
ing System outlined in Group 7 Cooling System for
procedure.
(20) Connect negative battery cable.
(21) With the DRB Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe
from rear (cowl side) exhaust manifold at the flex-
joint.(2) Disconnect Oxygen Sensor lead wire at the
rear exhaust manifold (Fig. 28).
(3) Remove bolts attaching cross-over pipe to
manifold (Fig. 30).
(4) Remove rear heat shield (Fig. 29).
(5) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
(6) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 31).
(7) Remove bolts fastening crossover pipe to front
exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.
(8) Inspect and clean manifolds. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
Install the gaskets with the numbers 1-3-5
embossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
32).
(1) Install rear exhaust manifold and tighten
attaching nuts to 20 N´m (175 in. lbs.).
Fig. 27 Intake Plenum Tightening Sequence
Fig. 28 Disconnect Up Stream Heated Oxygen
Sensor Connection
Fig. 29 Rear Exhaust Manifold Heat Shield
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

(2) Attach exhaust pipe to exhaust manifold and
tighten bolts to 28 N´m (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N´m (51 ft. lbs.)
(4) Install rear exhaust manifold heat shield (Fig.
29).
(5) Connect heated oxygen sensor lead (Fig. 28).
(6) Install front exhaust manifold and attach
exhaust crossover.
(7) Install front exhaust manifold heat shield and
tighten attaching screws to 15 N´m (130 in. lbs.) (Fig.
31).
INTAKE MANIFOLDÐ3.3/3.8L ENGINE
REMOVAL
(1) Remove windshield wiper module. Refer to
Group 8K Windshield Wiper and Washer Systems for
procedure.
(2) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(3) Drain cooling system. See Cooling System,
Group 7 for procedure.(4) Remove air inlet resonator to throttle body
hose assembly.
(5) Remove throttle cable. Refer to Group 14 Fuel
Systems for procedure. Remove wiring harness from
throttle cable bracket.
(6) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 33).
(7) Remove EGR transducer connector.
(8) Remove vacuum hose harness from throttle
body (Fig. 33).
(9) Remove PCV and brake booster hoses from air
intake plenum.
Fig. 30 Crossover Pipe
Fig. 31 Front Exhaust Manifold Heat Shield
Fig. 32 Identify Exhaust Manifold Gaskets
Fig. 33 Electrical and Vacuum Connection to
Throttle Body
11 - 12 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)

(25) Remove intake manifold bolts. Remove intake
manifold.
(26) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(27) Remove intake manifold seal retainers screws
(Fig. 43). Remove intake manifold gasket.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Place a drop (approximately 1/4 in. diameter)
of MopartSilicone Rubber Adhesive Sealant or
equivalent, onto each of thefourmanifold to cylinder
head gasket corners (Fig. 44).(3) Carefully install the new intake manifold gas-
ket (Fig. 43). Torque end seal retainer screws to 12
N´m (105 in. lbs.).
(4) Install intake manifold and bolts and torque to
1 N´m (10 in. lbs.). Then torque bolts to 22 N´m (200
in. lbs.) in sequence shown in (Fig. 42). Then torque
again to 22 N´m (200 in. lbs.). After intake manifold
is in place,inspect to make sure seals are in
place.
Fig. 38 Intake Manifold Plenum Bolts and Nuts
Fig. 39 Fuel Rail Attaching Bolts
Fig. 40 Coolant Temperature Sensor Electrical
Connector
Fig. 41 Fuel Rail Removal
11 - 14 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
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)