1996 CHRYSLER VOYAGER battery

to Group 8W for wiring connector and circuitry infor-
mation. Repair the wire harness if an open circuit is
indicated.
(4) After tests are completed, connect electrical
connector to sensor.
GLOW PLUG TEST
Hard starting or a rough idle after starting may be
caused by one or more defective glow plugs. Before
testing the glow plugs, a test of the glow plug relay
should be performed. This will ensure that 12V+ is
available at the plugs when starting the engine.
Refer to the Glow Plug Relay Test for information.
For accurate test results, the glow plugs should be
removed from the engine. The plugs must be checked
when cold.Do not check the plugs if the engine
has recently been operated. If plugs are
checked when warm, incorrect amp gauge
readings will result.
Use Churchill Glow Plug Tester DX.900 or an
equivalent (Fig. 14) for the following tests. This
tester is equipped with 4 timer lamps.
(1) Remove the glow plugs from the engine. Refer
to Glow Plug Removal/Installation.
(2) Attach the red lead of the tester to the 12V+
(positive) side of the battery.
(3) Attach the black lead of the tester to the 12V±
(negative) side of the battery.
(4) Fit the glow plug into the top of the tester and
secure it with the spring loaded bar (Fig. 14).
(5) Attach the third lead wire of the tester to the
electrical terminal at the end of the glow plug.(6) When performing the test, the tester button
(Fig. 14) should be held continuously without release
for 20 seconds as indicated by the 4 timer lamps.
Each illuminated lamp represents a 5 second time
lapse.
(a) Press and hold the tester button (Fig. 14)
and note the amp gauge reading. The gauge read-
ing should indicate a momentary, initial current
draw (surge) of approximately 25 amps. After the
initial surge, the amp gauge reading should begin
to fall off. The glow plug tip should start to glow
an orange color after 5 seconds. If the tip did not
glow after 5 seconds, replace the glow plug. Before
discarding the glow plug, check the position of the
circuit breaker on the bottom of the plug tester. It
may have to be reset. Reset if necessary.
(b) Continue to hold the tester button while
observing the amp gauge and the 4 timer lamps.
When all 4 lamps are illuminated, indicating a 20
second time lapse, the amp gauge reading should
indicate a 9±12 amp current draw. If not, replace
the glow plug. Refer to Glow Plug Removal/Instal-
lation.
(7) Check each glow plug in this manner using one
20 second cycle. If the glow plug is to be retested, it
must first be allowed to cool to room temperature.
WARNING: THE GLOW PLUG WILL BECOME
EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the glow plug from the tester.
GLOW PLUG RELAY TEST
The glow plug relay is located in the engine com-
partment on the left±inner fender (Fig. 15).
When the ignition (key) switch is placed in the ON
position, a signal is sent to the PCM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the PCM will deter-
mine if, when and for how long a period the glow
plug relay should be activated. This is done before,
during and after the engine is started. Whenever the
glow plug relay is activated, it will control the 12V+
100 amp circuit for the operation of the four glow
plugs.
The Glow Plug lamp is tied to this circuit. Lamp
operation is also controlled by the PCM.
With a cold engine, the glow plug relay and glow
plugs may be activated for a maximum time of 200
seconds. Refer to the Glow Plug Control chart for a
temperature/time comparison of glow plug relay oper-
ation.
Fig. 14 Typical Glow Plug Tester
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 51
DIAGNOSIS AND TESTING (Continued)

In this chart, Pre±Heat and Post±Heat times are
mentioned. Pre±heat is the amount of time the glow
plug relay circuit is activated when the ignition (key)
switch is ON, but the engine has yet to be started.
Post±heat is the amount of time the glow plug relay
circuit is activated after the engine is operating. The
Glow Plug lamp will not be illuminated during the
post±heat cycle.
TESTING:
Disconnect and isolate the electrical connectors
(Fig. 16) at all four glow plugs. With the engine cool
or cold, and the key in the ON position, check for
10±12 volts + at each electrical connector. 10±12 volts
+ should be at each connector whenever the PCM is
operating in the pre±heat or post±heat cycles (refer
to the following Glow Plug Control chart).Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors.If 10±12
volts + is not available at each connector, check con-
tinuity of wiring harness directly to the relay. If con-
tinuity is good directly to the relay, the fault is either
with the relay or the relay input from the PCM. To
test the relay only, refer to RelaysÐOperation/Test-
ing in this section of the group. If the relay test is
good, refer to the DRB scan tool.
Diagnostic Trouble Codes:Refer to On-Board
Diagnostics in Group 25, Emission Control System
for a list of Diagnostic Trouble Codes (DTC's) for cer-
tain fuel system components.
RELAYSÐOPERATION/TESTING
The following description of operation and
tests apply only to the Diesel PCM and other
relays. The terminals on the bottom of each relay
are numbered (Fig. 17).
OPERATION
²Terminal number 30 is connected to battery volt-
age. For both the Diesel and other relays, terminal
30 is connected to battery voltage at all times.
²The PCM grounds the coil side of the relay
through terminal number 85.
²Terminal number 86 supplies voltage to the coil
side of the relay.
²When the PCM de-energizes the Diesel PCM
and other relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off posi-
tion, voltage is not supplied to the rest of the circuit.
Terminal 87A is the center terminal on the relay.
Fig. 15 Glow Plug Relay Location
Fig. 16 Wiring Connection at Glow Plug
GLOW PLUG CONTROL
14 - 52 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

(2) Remove the sensor mounting bolts.
(3) Remove the sensor.
INSTALLATION
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the sensor mounting bolt to
19 N´m (14 ft. lbs.) torque.
(3) Connect the electrical connector to the sensor.
ENGINE COOLANT TEMPERATURE SENSOR
The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 19).
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Partially drain cooling system. Refer to Group
7, Cooling.
(2) Disconnect electrical connector from sensor.
(3) Remove sensor from cylinder head.
INSTALLATION
(1) Install a new copper gasket to sensor.
(2) Install sensor to cylinder head.
(3) Tighten sensor to 18 N´m (13 ft. lbs.) torque.
(4) Connect electrical connector to sensor.
(5) Replace any lost engine coolant. Refer to Group
7, Cooling System.
GLOW PLUGS
The glow plugs are located above each fuel injector
(Fig. 20). Four individual plugs are used.
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Clean the area around the glow plug with com-
pressed air before removal.
(3) Disconnect electrical connector (Fig. 21) at glow
plug.
(4) Remove the glow plug (Fig. 20) from cylinder
head.
Fig. 18 Engine Speed SensorFig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Glow Plug
14 - 54 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Apply high±temperature anti±seize compound
to glow plug threads before installation
(2) Install the glow plug into the cylinder head.
Tighten to 23 N´m (203 in. lbs.) torque.
(3) Connect battery cable to battery.
GLOW PLUG RELAY
The glow plug relay is located in the engine com-
partment on the left±inner fender (Fig. 22).
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Remove relay mounting bolt.(3) Disconnect electrical connector at relay and
remove relay.
INSTALLATION
(1) Check condition of electrical connector for dam-
age or corrosion. Repair as necessary.
(2) Install electrical connector to relay.
(3) Install relay to inner fender.
(4) Connect battery cable to battery.
POWERTRAIN CONTROL MODULE (PCM)
The PCM is mounted to a bracket located in the
center consule in front of the air bag module (Fig.
23).
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Loosen the 68±Way connector (Fig. 23). The
electrical connector has a sliding bar which moves
inward to lock or outward to unlock.
(3) Remove the electrical connector by pulling
straight out.
(4) Remove PCM.
INSTALLATION
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro-
sion, being spread apart, bent or misaligned. Also
inspect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Engage 68±way connector into PCM. Move
slide bar to lock connector.
(3) Connect negative cable to battery.
VEHICLE SPEED SENSOR
The vehicle speed sensor (Fig. 24) is located on the
extension housing of the transmission.
Fig. 21 Glow Plug Electrical Connector
Fig. 22 Glow Plug Relay Location
Fig. 23 PCM Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 55
REMOVAL AND INSTALLATION (Continued)

REMOVAL AND INSTALLATION
2.4 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove the (-) negative battery cable from the
battery and isolate cable.
(4) Remove the drive belt from the power steering
pump pulley. See Cooling, Group 7 for detailed
removal procedure.
(5) Loosenbut do not removethe nut attaching
the front bracket for the power steering pump (Fig.
3) to the aluminum mounting bracket.
(6) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(7) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.(8) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(9) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 4).
(10) Raise the heat sleeve on the power steering
return hose to expose the hose to steel tube connec-
tion (Fig. 5). Remove the hose from the power steer-
ing fluid return line on the front suspension cradle
(Fig. 5). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed return hose.
Fig. 3 Power Steering Pump Bracket Attaching Nut
Fig. 4 Exhaust Positioned For Removing Power
Steering Pump
Fig. 5 Power Steering Return Hose At Return Line
NSSTEERING 19 - 11

(18) Remove the 3 previously loosened bolts
attaching the front bracket to the power steering
pump and separate the power steering pump from
the front bracket prior to removing the pump from
the vehicle.
(19) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel are of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket and loosely install nut to hold
pump in place (Fig. 9).
(3) Install the front bracket on the power steering
pump and loosely install the 3 mounting bolts (Fig.
10). Then install the nut and bolt attaching the front
bracket to the cast bracket (Fig. 10).
(4) Tighten the 3 power steering pump mounting
bolts (Fig. 10) to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(5) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 8). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(6) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 8).Be sure hose clamps are properly
reinstalled.
(7) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 7).Be sure hose is
clear of accessory drive belts all hose clamps
are properly reinstalled.
(8) Install the power steering pump drive belt on
pulley. See Cooling, Group 7 for detailed installation
procedure.
(9) Install the accessory drive splash shield (Fig.
6).
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 5).
(11) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is requiredto prevent the overheating of the power steering
hoses.
(12) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 5).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(13) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(14) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(15) Lower vehicle.
(16) Adjust the power steering pump drive belt.
See Cooling, Group 7 for detailed adjustment proce-
dure.
(17) Tighten the top nut and bottom bolt on the
power steering pump front mounting bracket (Fig. 3)
to a torque of 54 N´m (40 ft. lbs.).
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(18) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(19) Install cap on power steering fluid reservoir.
(20) Connect the negative battery cable on the
negative battery post.
(21) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.0 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
NSSTEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)

(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.
(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.3/3.8 LITER POWER STEERING PUMP
REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove cap from power steering fluid reser-
voir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(7) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 17).
(8) Raise the heat sleeve on the power steering
hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle (Fig. 18).
Allow the remaining power steering fluid to drain
from the pump and fluid reservoir through the
removed return hose.
(9) Remove the accessory drive splash shield (Fig.
19).
Fig. 17 Exhaust Position For Removing Power
Steering Pump
Fig. 18 Power Steering Return Hose At Return Line
Fig. 19 Accessory Drive Splash Shield
19 - 16 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 21). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 21).Be sure hose clamps are prop-
erly reinstalled.
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21).Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). See
Cooling, Group 7 for detailed installation procedure.
(8) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig.
18).
(9) Install a screw type hose clamp on the power
steering hose to steel tube connection.Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N´m (18 in. lbs.).
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 18). This is required
to keep the power steering hoses from becoming
overheated.
(10) When used, properly position the protective
heat sleeves on the power steering hoses (Fig. 18).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
19).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING FLUID RESERVOIR TO PUMP
SUPPLY HOSE
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 24).
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove power steering fluid supply hose rout-
ing clip (Fig. 25) from stud in strut tower.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 24 Fluid Supply Hose At Power Steering Fluid
Reservoir
Fig. 25 Power Steering Fluid Hose Routing Clip
19 - 18 STEERINGNS
REMOVAL AND INSTALLATION (Continued)