1996 CHRYSLER VOYAGER fuel filter

(7) Inspect the starter motor and starter solenoid
connections for tightness and corrosion.
(8) Verify that the electrical connector is firmly
connected to the fuel shutdown solenoid. Inspect the
connector for corrosion or damaged wires. The sole-
noid is mounted to the rear of the injection pump
(Fig. 15).
(9) Verify that the fuel heater electrical connector
is firmly attached to the filter bowl at the bottom of
the fuel filter/water separator. Inspect the connector
for corrosion or damaged wires.
(10) Verify that the electrical pigtail connector
(sensor connector) (Fig. 16) for the fuel injector sen-
sor is firmly connected to the engine wiring harness.
Inspect the connector for corrosion or damaged wires.
This sensor is used on the #1 cylinder injector only.
(11) Verify that the electrical pigtail connector
(sensor connector) (Fig. 17) for the fuel timing sole-
noid is firmly connected to the engine wiring har-
ness. Inspect the connector for corrosion or damaged
wires. The fuel timing solenoid is located on the bot-
tom of the fuel injection pump (Fig. 17).
(12) Inspect for exhaust system restrictions such
as pinched exhaust pipes or a collapsed or plugged
muffler.
(13) Verify that the harness connector is firmly
connected to the vehicle speed sensor (Fig. 18).
(14) Verify turbocharger wastegate operation.
Refer to Group 11, Exhaust System and Intake Man-
ifold Group for information.
(15) Verify that the harness connector is firmly
connected to the engine coolant temperature sensor.The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 19).
(16) Check for air in the fuel system. Refer to the
Air Bleed Procedure.
(17) Inspect all fuel supply and return lines for
signs of leakage.
(18) Be sure that the ground connections are tight
and free of corrosion. Refer to Group 8, Wiring for
locations of ground connections.
(19) Inspect the air cleaner element (filter) for
restrictions.
(20) Be sure that the turbocharger output hose is
properly connected to the charge air cooler (inter-
cooler) inlet tube. Verify that the charge air cooler
output hose is properly connected to the cooler and
Fig. 15 Fuel Shutdown Solenoid Location
Fig. 16 Fuel Injector Sensor
Fig. 17 Fuel Timing Solenoid
14 - 10 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

the intake manifold. Refer to Group 11, Exhaust Sys-
tem and Intake Manifold for information.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not leaking. The pump is
located on the front of engine (internal) and is driven
from the crankshaft gear and chain (Fig. 20). Discon-
nect the hose and check for minimum vacuum from
the pump. Refer to Group 5, Brake System for spec-
ifications and procedures.(22) Be sure that the accessory drive belt is not
damaged or slipping.
(23) Verify there is a good connection at the engine
speed sensor. Refer to the Fuel Injection System in
this section for location of the engine speed sensor
location.
(24) Verify there is a good connection at the Mass
Air Flow Sensor, which is a part of the air intake
assembly.
AIR IN FUEL SYSTEM
Air will enter the fuel system whenever the fuel
supply lines, fuel filter/water separator, fuel filter
bowl, injection pump, high±pressure lines or injectors
are removed or disconnected. Air will also enter the
fuel system whenever the fuel tank has been run
empty.
Air trapped in the fuel system can result in hard
starting, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.
Inspect the fuel system from the fuel tank to the
injectors for loose connections. Leaking fuel is an
indicator of loose connections or defective seals. Air
can also enter the fuel system between the fuel tank
and the injection pump. Inspect the fuel tank and
fuel lines for damage that might allow air into the
system.
For air bleeding, refer to Air Bleed Procedure in
the Service Procedures section of this group.
Fig. 18 Vehicle Speed SensorÐTypical
Fig. 19 Engine Coolant Temperature Sensor
Location
Fig. 20 Vacuum Pump at Front of Engine
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 11
DIAGNOSIS AND TESTING (Continued)

A defective fuel injection pump, defective fuel tim-
ing solenoid or misadjusted mechanical pump timing
can cause starting problems or prevent the engine
from revving up. It can also cause:
²Engine surge at idle
²Rough idle (warm engine)
²Low power
²Excessive fuel consumption
²Poor performance
²Low power
²Black smoke from the exhaust
²Blue or white fog like exhaust
²Incorrect idle or maximum speed
The electronically controlled fuel pump has no
mechanical governor like older mechanically con-
trolled fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fastening the wiring
pigtail to the side of the pump.The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOW±PRESSURE LINES
Restricted or Plugged supply lines or fuel filter can
cause a timing fault that will cause the PCM to oper-
ate the engine in a ªLimp Homeº mode. See the
introduction of the Fuel Injection System in this
group for more information on the Limp Home mode.
Fuel supply line restrictions can cause starting prob-
lems and prevent the engine from revving up. The
starting problems include; low power and blue or
white fog like exhaust. Test all fuel supply lines for
restrictions or blockage. Flush or replace as neces-
sary. Bleed the fuel system of air once a fuel supply
line has been replaced. Refer to the Air Bleed Proce-
dure section of this group for procedures.
HIGH±PRESSURE LINES
Restricted (kinked or bent) high±pressure lines can
cause starting problems, poor engine performance
and black smoke from exhaust.
Examine all high±pressure lines for any damage.
Each radius on each high±pressure line must be
smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high±pres-
sure fuel lines with the correct replacement line.
CAUTION: The high±pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
FUEL SHUTDOWN SOLENOID TEST
Since diesel fuel injection does not use spark plugs
to start combustion, the only way to stop the engine
is to cut off the fuel supply. This is done with the
Fuel Shutdown Solenoid. If the engine cranks, but
refuses to start, it may be caused by a defective fuel
shutdown solenoid.
The fuel shutdown solenoid is not controlled
or operated by the PCM.Voltage to operate the
solenoid is supplied from the ignition (key) switch.
NOTE: Although the fuel shutdown solenoid is not
operated by the PCM, if the Fuel Shutdown Solenoid
has been disconnected, and the key turned on, the
PCM will sense that the solenoid is not in the circuit,
and will switch to a ªLimp Homeº mode. After recon-
necting the solenoid, the PCM will have to be reset
by clearing the codes with the DRBIII scan tool, or
disconnecting the vehicle's battery for several min-
utes. The DRBIII scan tool is the preferred method
for resetting the PCM. Refer to the 1998 GS 2.5L Die-
sel Powertrain Diagnostic Manual for procedure.
The fuel shutdown (shut±off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
±pressure fuel injection pump. The solenoid is
mounted to the rear of the injection pump (Fig. 23).
The solenoid controls starting and stopping of the
engine regardless of the position of the accelerator
pedal. When the ignition (key) switch is OFF, the sole-
noid is shut off and fuel flow is not allowed to the fuel
injection pump. When the key is placed in the ON or
Fig. 23 Fuel Shutdown Solenoid Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 13
DIAGNOSIS AND TESTING (Continued)

START positions, fuel supply is allowed at the injec-
tion pump.
(1) Disconnect the electrical pigtail connector (test
connector) (Fig. 23) from the main engine wiring har-
ness. Do not disconnect wiring directly at solenoid.
(2) Connect the leads of a voltmeter between a
good ground and the disconnected engine wiring har-
ness.
(3) Turn the key to the ON position. Do not
attempt to start engine.
(4) 12V+ should be observed at wiring harness. If
not, refer to Group 8, Wiring for wiring schematics
and repair as necessary.
(5) T
urn the key to the START position. 12V+ should
be observed at wiring harness. If not, refer to Group 8,
Wiring for wiring schematics and repair as necessary.
The fault may be in the ignition (key) switch.
12V+ must be observed in both the ON and START
positions. If 12V+ was observed, proceed to the next
step.
(6) With key still in the ON position, connect and
disconnect the wiring harness to the solenoid. As this
is done, a clicking noise should be heard coming from
the solenoid. If not, replace solenoid. Refer to Fuel
Shutdown Solenoid in the Removal/Installation sec-
tion of this group for procedures.
HIGH-PRESSURE FUEL LINE LEAK TEST
High±pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 45,000 KPA (6526 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH±PRESSURE
FUEL LEAKS. DO NOT GET YOUR HAND, OR ANY
PART OF YOUR BODY NEAR A SUSPECTED LEAK.
INSPECT FOR HIGH±PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high±pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 24). If a high±pressure line con-
nection is leaking, bleed the system and tighten the
connection. Refer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high±pressure fuel lines with the correct
replacement line.
CAUTION: The high±pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high±pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high±pressure
fuel line is necessary.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and Intake
Manifold for information.
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certain amount of air may become trapped in the
fuel system when fuel system components are ser-
viced or replaced. Bleed the system as needed after
fuel system service according to the following proce-
dures.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Some air enters the fuel system when the fuel fil-
ter or injection pump supply line is changed. This
small amount of air is vented automatically from the
injection pump through the fuel drain manifold tubes
if the filter was changed according to instructions.
Ensure the bowl of the fuel filter/water separator is
full of fuel
It may be necessary to manually bleed the system
if:
²The bowl of the fuel filter/water separator is not
partially filled before installation of a new filter
²The injection pump is replaced
Fig. 24 Typical Test for Leaks with Cardboard
14 - 14 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) Disconnect electrical connector.
(2) Remove accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.
INSTALLATION
(1) Place accelerator pedal assembly over studs
protruding from floor pan. Tighten mounting nuts to
5 N´m (46 in. lbs.) torque.
(2) Connect electrical connector.
(3) Before starting the engine, operate the acceler-
ator pedal to check for any binding.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose clamp at Mass Air Flow Sensor.
(2) Remove hose from Mass Air Flow Sensor.(3) Loosen 2 clamps holding air cleaner housing
halves together.
(4) Remove left side of air cleaner housing.
(5) Remove element from air cleaner housing.
INSTALLATION
(1) Install a new element in housing.
(2) Position left side of housing.
(3) Snap clamps into place.
(4) Install hoses and clamps.
FUEL DRAIN TUBES
The fuel drain tubes (Fig. 28) are low±pressure
type.
Pull each tube from the injector for removal. Push
on for installation. Clamps are not required for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator is located in the
engine compartment on the right side near the shock
tower. (Fig. 29).
The fuel filter/water separator assembly contains
the fuel filter, fuel heater element, and fuel drain
valve (Fig. 29).
DRAINING WATER FROM FILTER BOWL
Moisture (water) collects at the bottom of the filter/
separator in a plastic bowl. Water entering the fuel
injection pump can cause serious damage to the
pump.Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
Fig. 27 Accelerator Pedal Mounting-Typical
Fig. 28 Fuel Drain Tubes
14 - 16 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the filter/separator bowl is
equipped with a drain valve (Fig. 29). The drain
valve is equipped with a fitting. Attach a piece of
rubber hose to this fitting. This hose is to be used as
a drain hose.
(2) Place a drain pan under the drain hose.
(3) With the engine not running, open the drain
valve (unscrewÐdrain valve has right hand threads)
from the filter/separator bowl. To gain access to this
fitting, the two filter±to±mounting bracket nuts (Fig.
29) may have to be loosened a few turns.
(4) Hold the drain open until clean fuel exits the
drain.
(5) After draining, close drain valve.
(6) Remove rubber drain hose.
(7) Dispose of mixture in drain pan according to
applicable local or federal regulations.
FUEL FILTER REMOVAL
(1) Drain all fuel and/or water from fuel filter/wa-
ter separator assembly. Refer to the previous Drain-
ing Water From Filter Bowl.
(2) Unplug the electrical connectors at bottom of
plastic bowl.
(3) Remove plastic bowl from bottom of fuel filter
(unscrews).
(4) Remove fuel filter from bottom of filter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Clean bottom of fuel filter base.
(2) Apply clean diesel fuel to new fuel filter gasket.
(3) Install and tighten filter to filter base. The bev-
eled part of the rubber gasket should be facing up
towards the filter base.
(4) Clean the inside of bowl with a soap and water
mixture before installation. Carefully clean any resi-
due between the two metal probes at the top of the
water±in±fuel sensor. Do not use chemical cleaners
as damage to the plastic bowl may result.
(5) Pour diesel fuel into the plastic bowl before
installing bowl to bottom of fuel filter. Do this to help
prevent air from entering fuel injection pump while
attempting to starting engine.
(6) Install filter bowl to bottom of filter.
(7) Install the electrical connectors at bottom of
bowl.
(8) Tighten the filter±to±mounting bracket nuts
(Fig. 29) to 28 N´m (250 in. lbs.) torque.
FUEL HEATER
If the fuel heater element needs replacement, the
plastic filter bowl assembly must be replaced. Refer
to Fuel Filter/Water Separator for information.
FUEL HEATER RELAY
The fuel heater relay is located in the PDC. For
the location of the relay within the PDC (Fig. 30),
refer to label on PDC cover.
Fig. 29 Fuel Filter/Water Separator Location
Fig. 30 Power Distribution Center (PDC) Location
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 17
REMOVAL AND INSTALLATION (Continued)

FUEL DELIVERY SYSTEMÐ2.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ELECTRIC FUEL PUMP.................. 28
FUEL DELIVERY SYSTEM................ 28
FUEL INJECTORS...................... 28
FUEL LEVEL SENSOR................... 28
FUEL PRESSURE REGULATOR........... 28
FUEL PUMP MODULE................... 28
FUEL TANK........................... 28
PRESSURE-VACUUM FILLER CAPÐ
2.0L ENGINE......................... 28
QUICK-CONNNECT FITTINGSÐ
2.0L ENGINE......................... 28
DIAGNOSIS AND TESTING
FUEL INJECTORSÐ2.0L ENGINE.......... 29
FUEL LEVEL SENSORÐ2.0L ENGINE....... 28
FUEL PUMP PRESSURE TESTÐ
2.0L ENGINE......................... 28SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.0L ENGINE............ 29
HOSES AND CLAMPSÐ2.0L ENGINE....... 29
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE . 29
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL.................. 31
FUEL FILTERÐ2.0L ENGINE.............. 29
FUEL INJECTORS...................... 30
FUEL LEVEL SENSORÐ2.0L ENGINE....... 30
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PRESSURE REGULATORÐ
2.0L ENGINE......................... 29
FUEL PUMP MODULEÐ2.0L ENGINE....... 29
FUEL TANKÐ2.0L ENGINE............... 30
TORQUE SPECIFICATION................ 31
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
Refer to the Fuel Delivery Sytem in the Fuel Deliv-
ery Section of group 14 for the 2.4/3.0/3.3/3.8L
engines for more information.
FUEL PUMP MODULE
Refer to the Fuel Pump Module for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14.
ELECTRIC FUEL PUMP
Refer to the Electric Fuel Pump for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System Section of
group 14 for more information.
FUEL LEVEL SENSOR
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL PRESSURE REGULATOR
Refer to the Fuel Pressure Regulator for the 2.4/
3.0/3.3/3.8L engines in the Fuel Delivery System sec-
tion of group 14 for more information.
FUEL INJECTORS
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
FUEL TANK
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
PRESSURE-VACUUM FILLER CAPÐ2.0L ENGINE
Refer to the Pressure-Vacuum Filler Cap for the
2.4/3.0/3.3/3.8L engines in the Fuel Delivery System
section of group 14 for more information.
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE
Refer to the Quick Connect Fittings for the 2.4/3.0/
3.3/3.8L engines in the Fuel Delivery System section
of group 14 for more information.
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TESTÐ2.0L ENGINE
Refer to the Fuel Pressure Test for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
FUEL LEVEL SENSORÐ2.0L ENGINE
Refer to the Fuel Level Sensor for the 2.4/3.0/3.3/
3.8L engines in the Fuel Delivery System section of
group 14 for more information.
14 - 28 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS

FUEL INJECTORSÐ2.0L ENGINE
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.0L ENGINE
Refer to the Fuel System Pressure Release Proce-
dure for the 2.4/3.0/3.3/3.8L engines in the Fuel
Delivery System section of group 14 for more infor-
mation.
HOSES AND CLAMPSÐ2.0L ENGINE
Refer to Hoses and Clamps for the 2.4/3.0/3.3/3.8L
engines in the Fuel Delivery System section of group
14 for more information.
QUICK-CONNNECT FITTINGSÐ2.0L ENGINE
Refer to the Quick Connect Fittings for the 2.4/3.0/
3.3/3.8L engines under Service Procedures in the
Fuel Delivery System section of group 14 for more
information.
REMOVAL AND INSTALLATION
FUEL FILTERÐ2.0L ENGINE
Refer to the Fuel Filter for the 2.4/3.0/3.3/3.8L
engines under Removal and Installation in the Fuel
Delivery System section of group 14 for more infor-
mation.
FUEL PUMP MODULEÐ2.0L ENGINE
Refer to the Fuel Pump Module for the 2.4/3.0/3.3/
3.8L engines under Removal and Installation in theFuel Delivery System section of group 14 for more
information.
FUEL PRESSURE REGULATORÐ2.0L ENGINE
Refer to the Fuel Pressure Rgulator for the 2.4/3.0/
3.3/3.8L engines under Removal and Installation in
the Fuel Delivery System section of group 14 for
more information.
FUEL PRESSURE REGULATORÐ2.0L ENGINE
Refer to the Fuel Pressure Regulator for the 2.4/
3.0/3.3/3.8L engines under Removal and Installation
in the Fuel Delivery System section of group 14 for
more information.
Fig. 1 Fuel Pressure Test PortÐ2.0L
Fig. 2 FUEL LEVEL SENSOR DIAGNOSIS
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 29
DIAGNOSIS AND TESTING (Continued)