1996 CHRYSLER VOYAGER Index

8W-01 GENERAL INFORMATION
INDEX
page page
DESCRIPTION AND OPERATION
CIRCUIT FUNCTIONS..................... 4
CIRCUIT INFORMATION................... 4
CONNECTOR INFORMATION............... 7
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES.................... 8
INTRODUCTION......................... 1
NOTES, CAUTIONS, and WARNINGS......... 7
POSITIVE TEMPERATURE COEFFICIENT...... 8
SECTION IDENTIFICATION................. 5
SPLICE LOCATIONS...................... 7
SYMBOLS.............................. 5
TAKE OUTS............................. 8
TERMINOLOGY.......................... 7
DIAGNOSIS AND TESTING
INTERMITTENT AND POOR CONNECTIONS.... 9TROUBLESHOOTING TESTS................ 9
TROUBLESHOOTING TOOLS............... 8
TROUBLESHOOTING WIRING PROBLEMS.... 10
SERVICE PROCEDURES
CONNECTOR AND TERMINAL REPLACEMENT . 12
CONNECTOR REPLACEMENT.............. 11
DIODE REPLACEMENT................... 14
TERMINAL REPLACEMENT................ 13
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS........................ 12
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS........................ 11
WIRING REPAIR........................ 10
SPECIAL TOOLS
WIRING/TERMINAL...................... 14
DESCRIPTION AND OPERATION
INTRODUCTION
Chrysler wiring diagrams are designed to provide
information regarding the vehicles wiring content. In
order to effectively use Chrysler wiring diagrams to
diagnose and repair a Chrysler vehicle, it is impor-
tant to understand all of their features and charac-
teristics.
Diagrams are arranged such that the power (B+)
side of the circuit is placed near the top of the page,
and the ground (B-) side of the circuit is placed near
the bottom of the page.
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition.Components are shown two ways. A solid line
around a component indicates that the component is
complete. A dashed line around a component indi-
cates that the component being shown is not com-
plete. Incomplete components have a reference
number to indicate the page where the component is
shown complete.
It is important to realize that no attempt is made
on the diagrams to represent components and wiring
as they appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. In
addition, switches and other components are shown
as simply as possible, with regard to function only.
NS/GS8W-01 GENERAL INFORMATION 8W - 01 - 1

8W-02 COMPONENT INDEX
Component Page
2-4 Pressure Switch.....................8W-31
2-4 Solenoid...........................8W-31
A/C Compressor Clutch..................8W-42
A/C Compressor Clutch Relay...........8W-10, 42
A/C Heater Control.....................8W-42
A/C On Indicator.......................8W-42
A/C Pressure Transducer..............8W-30, 42
A/C Switch............................8W-42
A/C Zone Door Actuator..................8W-42
ABS Warning Lamp..................8W-35, 46
Accelerator Pedal Position Sensor..........8W-30
Airbag Control Module...................8W-43
Airbag Indicator Lamp...................8W-43
Airbag Warning Lamp...................8W-46
All Wheel Drive Solenoid.................8W-31
Ambient Air Temperature Sensor...........8W-49
Ash Receiver Lamp.....................8W-44
Automatic Day/Night Mirror..............8W-44
Automatic Shut Down Relay............8W-10, 30
Splice Information......................8W-70
Back-Up Lamp.........................8W-51
Back-Up Switch.....................8W-44, 51
Battery...............................8W-20
Blend Door Actuator.....................8W-42
Body Control Module....................8W-45
Brake Pressure Switch...................8W-46
Brake Warning Lamp....................8W-46
Camshaft Position Sensor................8W-30
Center Dome Lamp.....................8W-44
Center High Mounted Stop Lamp..........8W-51
Cigar/Accessory Relay...................8W-41
Clockspring.......8W-10, 15, 30, 33, 39, 40, 41, 43
Cluster Illumination Lamps...............8W-40
Clutch Interlock Switch...............8W-12, 21
Clutch Interlock Switch Jumper......8W-12, 21, 31
Clutch Switch.......................8W-30, 33
Combination Flasher/DRL Module. . . .8W-50, 51, 52
Combination Relays.....................8W-54
Compass/Mini-Trip Computer..............8W-49
Control Sleeve Sensor....................8W-30
Controller Anti-Lock Brake...............8W-35
Courtesy Lamp Relay...........8W-10, 12, 44, 50
Crank Case Heater......................8W-30
Crankshaft Position Sensor...............8W-30
Cruise Indicator Lamp...................8W-40
Data Link Connector....................8W-30
Diesel Power Relay...................8W-10, 30
Dome Lamp Switch.....................8W-50
Door Ajar Indicator Lamp................8W-40
Door Ajar Switches................8W-39, 40, 44
Door Lock Relay........................8W-61
Speakers..............................8W-47Component Page
Door Unlock Relay......................8W-61
Oxygen Sensors........................8W-30
Door Ajar Switches.............8W-39, 40, 44, 45
Door Arm/Disarm Switches.............8W-39, 61
Door Courtesy Lamps....................8W-44
Door Lock Motors.......................8W-61
Door Lock Switches.....................8W-61
Door Unlock Relays.....................8W-61
Heated Seat Backs......................8W-63
Heated Seat Cushions...................8W-63
Heated Seat Modules....................8W-63
Heated Seat Switches....................8W-63
Power Mirrors.........................8W-62
Power Seat Switches....................8W-63
Power Window Switches..................8W-60
Seat Motors...........................8W-63
Window Motors........................8W-60
Radiator Fans.........................8W-42
Dump Solenoid.........................8W-33
EGR Solenoid..........................8W-30
Electric Wiper De-Icer...................8W-48
Electronic PRNDL Indicator...............8W-40
Engine Coolant Temperature Gauge.........8W-40
Engine Coolant Temperature Lamp.........8W-46
Engine Coolant Temperature Sensor........8W-30
Engine Oil Pressure Switch...............8W-46
Engine Speed Sensor....................8W-30
Engine Starter Motor....................8W-21
Engine Starter Motor Relay............8W-10, 21
Evap Leak Detection Pump...............8W-30
Evap/Purge Solenoid....................8W-30
Evaporator Temperature Sensor............8W-42
Express Down Module...................8W-60
Flexible Fuel Sensor.....................8W-30
Fog Lamps............................8W-50
Fog Lamp Relay........................8W-50
Front Blower Motor.....................8W-42
Front Blower Motor Relay.............8W-10, 42
Front Blower Motor Resistor Block.........8W-42
Front Cigar Lighter/Power Outlet..........8W-41
Front Reading Lamp Defeat Switch.........8W-44
Front Reading Lamps/Switch..............8W-44
Front Washer Motor.....................8W-53
Front Wiper Switch.....................8W-53
Fuel Gauge............................8W-40
Fuel Heater...........................8W-30
Fuel Heater Relay...................8W-10, 30
Fuel Injectors..........................8W-30
Fuel Pump Module......................8W-30
Fuel Pump Relay....................8W-10, 30
Fuel Quantity Actuator..................8W-30
Fuel Shutdown Solenoid..................8W-30
NS/GS8W - 02 COMPONENT INDEX 8W - 02 - 1

Component Page
Fuel Tank Module...................8W-30, 45
Fuel Temperature Sensor.................8W-30
Fuel Timing Solenoid....................8W-30
Fuses (JB)............................8W-12
Fuses (PDC)...........................8W-10
Fusible Link.....................8W-20, 21, 63
Fusible Link A0........................8W-30
Fusible Link A11.......................8W-10
Fusible Link A54.......................8W-10
Grounds..............................8W-15
Generator.............................8W-20
Glove Box Lamp........................8W-44
Glow Plug Lamp.....................8W-30, 46
Glow Plugs............................8W-30
Glow Plug Relay........................8W-30
Headlamps............................8W-50
Headlamp Dimmer Switch..........8W-10, 46, 50
Headlamp Leveling Motors...............8W-50
Headlamp Switch.......................8W-50
Headlamp Washer......................8W-53
High Beam Indicator....................8W-46
High Beam Relay....................8W-10, 50
Headlamps............................8W-50
Horns................................8W-41
Hood Ajar Switch....................8W-39, 44
Horn Relay.........................8W-39, 41
Horn Switch.....................8W-10, 39, 41
HVAC Control.........................8W-42
Idle Air Control Motor...................8W-30
Ignition Coil Pack.......................8W-30
Ignition Switch.........................8W-10
Instrument Cluster.....................8W-40
Intake Air Temperature Sensor............8W-30
Intake Air Temperature/Manifold Absolute
Pressure Sensor.....................8W-30
Interior Lamps On Switch................8W-44
Junction Block.........................8W-12
Key-In Halo Lamp......................8W-44
Knock Sensor..........................8W-30
Lamp Assemblies.......................8W-51
License Lamp..........................8W-51
Liftgate Ajar Indicator Lamp..............8W-40
Liftgate Ajar Switch...............8W-39, 40, 44
Liftgate Arm/Disarm Switch............8W-39, 61
Liftgate Flood Lamps....................8W-44
Liftgate Lock Motor.....................8W-61
Low Beam Relay.....................8W-10, 50
Low Coolant Level Switch................8W-45
Low Fuel Warning Indicator Lamp..........8W-40
Low Oil Pressure Lamp..................8W-46
Low Washer Fluid Level Indicator Lamp.....8W-40
Low Washer Fluid Switch.................8W-53
Low/Reverse Pressure Switch..............8W-31
Low/Reverse Solenoid....................8W-31Component Page
Manifold Absolute Pressure Sensor.........8W-30
Memory Power Seat Switch...............8W-63
Seat Sensors...........................8W-63
Memory Seat/Mirror Module...........8W-62, 63
Memory Set Switch..................8W-62, 63
Message Center........................8W-46
Mid Reading Lamps.....................8W-44
Mode Door Actuator.....................8W-42
Name Brand Speaker Relay...............8W-47
Needle Movement Sensor.................8W-30
Odometer.............................8W-40
Output Shaft Speed Sensor...............8W-31
Overdrive Pressure Switch................8W-31
Overdrive Solenoid......................8W-31
Overhead Console.......................8W-49
Park Brake Switch...................8W-46, 50
Park Lamp Relay.........8W-10, 12, 44, 50, 51, 54
Park/Turn Signal Lamps.................8W-50
Airbag Squibs..........................8W-43
Power Distribution Center................8W-10
Power Folding Mirror Switch..............8W-62
Power Mirror Fold Relay.................8W-62
Power Mirror Switch....................8W-62
Power Mirror Unfold Relay...............8W-62
Power Seat Circuit Breaker............8W-62, 63
Powertrain Control Module...............8W-30
PTCs (JB).............................8W-12
Radiator Fan Disconnect.................8W-42
Radiator Fan Relays.....................8W-42
Radio................................8W-47
Radio Choke...........................8W-47
Reading Lamps........................8W-44
Rear A/C Heater Unit....................8W-42
Rear Blower Control Switches.............8W-42
Rear Cigar Lighter/Power Outlet...........8W-41
Rear Defogger On Indicator...............8W-42
Rear Dome Lamp.......................8W-44
Rear Fog Lamp.........................8W-51
Rear Fog Lamp Indicator.................8W-51
Rear Washer Motor.....................8W-53
Rear Washer Switch..................8W-42, 53
Rear Window Defogger...................8W-48
Rear Window Defogger Relay..............8W-48
Rear Window Defogger Switch..........8W-42, 48
Rear Wiper Delay On Indicator.........8W-42, 53
Rear Wiper Delay Switch..............8W-42, 53
Rear Wiper Motor.......................8W-53
Rear Wiper On Indicator..............8W-42, 53
Rear Wiper On Switch................8W-42, 53
Recirculate Mode Indicator................8W-42
Recirculate Mode Switch.................8W-42
Recirculation Door Actuator...............8W-42
Remote Keyless Entry Module.............8W-61
Repeater Lamps.....................8W-51, 52
8W - 02 - 2 8W - 02 COMPONENT INDEXNS/GS

Component Page
Seat Belt Indicator Lamp.................8W-40
Seat Belt Switch........................8W-40
Sentry Key Immobilizer Module............8W-39
Service Engine Soon Lamp.............8W-30, 46
Sliding Door Contacts....................8W-61
Sliding Door Lock Motors.................8W-61
Speed Control Switches...............8W-30, 33
Speedometer...........................8W-40
Stop Lamp Switch...................8W-33, 51
Stop/Turn Signal Relays..................8W-54
Tachometer............................8W-40
Tail/Stop Lamp.........................8W-51
Tail/Turn Signal Lamp................8W-51, 52
Throttle Position Sensor..................8W-30
Traction Control Switch..................8W-35
Trailer Tow Connector...................8W-54
Transmission Control Module..............8W-31
Transmission Control Relay............8W-10, 31
Transmission Control Solenoids............8W-31
Transmission Range Sensor...............8W-31
Trip Odometer.........................8W-40Component Page
Turbine Speed Sensor....................8W-31
Turbo Boost Pressure Sensor..............8W-30
Turn Indicators......................8W-46, 52
Turn Signal/Hazard Switch............8W-46, 52
Underdrive Solenoid.....................8W-31
Universal Garage Door Opener............8W-49
Vacuum Solenoid.......................8W-33
Vehicle Speed Control Servo...............8W-33
Vehicle Speed Sensor....................8W-30
Vent Motors...........................8W-60
Vent Solenoids.........................8W-33
Visor/Vanity Mirror Lamps................8W-44
Voltage Regulator.......................8W-20
Volts Indicator Lamp....................8W-40
VTSS Lamp........................8W-39, 46
Washer Module.........................8W-53
Wheel Speed Sensors....................8W-35
Wiper High/Low Relay...................8W-53
Wiper Module..........................8W-53
Wiper On Relay........................8W-53
NS/GS8W - 02 COMPONENT INDEX 8W - 02 - 3

8W-90 CONNECTOR/GROUND LOCATIONS
INDEX
page page
DESCRIPTION AND OPERATION
CONNECTOR/GROUND LOCATIONS.......... 1CONNECTOR/GROUND LOCATIONS......... 31
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of components, grounds, and connec-
tors in the vehicle. A index is provided. Use the wir-
ing diagrams in each section for connector/groundnumber identification. Refer to the index for the
proper figure number.CONNECTOR/GROUND LOCATIONS
For items not shown in this section a N/S is placed
in the Fig. column.
Component/
GroundColor Location Fig.
A/C
Compressor
ClutchBK Top of A/C
Compressor5, 6, 7,
8, 9
A/C-Heater
Control Module
C1NAT Rear of Control 11
A/C-Heater
Control Module
C2BK Rear of Control 11
A/C Pressure
TransducerGY RT Side Cowl 3
A/C Zone Door
ActuatorNAT LT Side of
HVAC15
Airbag Control
Module C1YL Rear of I.P.
Center Stack12
Airbag Contol
Module C2BK Rear of I.P.
Center Stack12
All Wheel Drive
SolenoidBK Near Fuel Tank 20
Ambient
Temperature
SensorBK On Radiator
Closure Panel4
Ash Receiver
LampRD At Lamp 10
Automatic
Day/Night MirrorBK At Mirror 15
B01 BK LT Kick Panel 18
B02 BK LT Kick Panel 18
B03 BK RT Kick Panel 18Component/
GroundColor Location Fig.
B09 BK Under Seat 16
B17 BK LT Quarter
Panel21
B23 BK RT of Steering
Column13
B33 BK LT Frame Rail 2
B56 RD Under Seat 16
B70 LT/GY LT Frame Rail 2
B75 BL Bottom of RT
B-Pillar12
B98 BK Rear of RT Tail N/S
B99 BK Rear of LT Tail
LampN/S
B120 BK LT Kick Panel N/S
Backup Lamp
Switch (M/T)BK On
Transmission5, 6, 8
Blend Door
ActuatorNAT LT Side of
HVAC15
Body Control
Module C1NAT On Junction
Block12, 13
Brake Pressure
SwitchBK On Master
Cylinder2
C19 Above RT
Vanity Mirror17
Camshaft
Position Sensor
2.4LBK Rear of
Cylinder Head6, 7
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1

8W-95 SPLICE LOCATIONS
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1SPLICE LOCATION INDEX.................. 1
SPLICE LOCATIONS (RHD)................ 15
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of the splices in this vehicle. A spliceindex is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for the proper splice number.
SPLICE LOCATION INDEX
Splice Number Location Fig.
BS01 Near Split for Tail Lamps 12
BS02 Near Fuel Tank T/O 12
BS03 Near Instrument Panel T/O 9
BS05 Near Instrument Panel T/O 9
BS05 (2.5L) Near MSA Controller T/O N/S
BS06 Near Instrument Panel T/O 9
BS06 (2.5L) Near MSA Controller T/O N/S
BS08 Near Instrument Panel T/O 9
BS16 Near Right Park Lamp T/O 1
BS17 Near Split for Tail Lamps 12
BS19 Near Horn T/O 1
BS30 (2.5L) Near Generator T/O 5
BS31 Near Left Headlamp Leveling
Motor T/O1
BS31 (2.5L) In BCM T/O 5
BS32 (2.5L) In BCM T/O N/S
BS33 (2.5L) In BCM T/O N/S
BS34 (2.5L) In BCM T/O N/S
BS40 (2.5L) In Engine Harness T/O 5
BS41 (2.5L) In Engine Harness T/O N/S
CS01 Above Right Rear Door 11
CS02 Above Right Rear Door 11
CS03 Right B-Pillar 11
CS04 Right B-Pillar 11
DS01 Near LT Power WDO T/O 10
ES01 In TCM T/O 7
ES01 (2.5L) Near Battery Positive Terminal
T/ON/SSplice Number Location Fig.
ES02 (2.0L) Near Camshaft Position
Sensor T/O3
ES02 (2.4L) Near Fuel Rail T/O 4
ES02 (2.5L) Near Engine Speed Sensor
T/O5
ES02
(3.3L,3.8L)Near Transmission T/O 6
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03
(3.3L,3.8L)Near Body Ground T/O 7
ES05 (2.4L) Near Knock Sensor T/O 4
ES05 (2.5L) In Fuel Injection Pump T/O 5
ES05
(3.3L,3.8L)Near Transmission T/O 6
ES06 (2.5L) Near Needle Movement
Sensor T/O5
ES06
(3.3L,3.8L)Near Transmission T/O N/S
ES07 (2.0L) Near Engine Ground T/O 2
ES07 (2.5L) Near Battery Negative
Terminal T/ON/S
ES07 (2.4L) Near Body Ground T/O 4, 7
ES07
(3.3L,3.8L)Near Battery Negative
Terminal T/O6
ES08
(3.3L,3.8L)Near Transmission T/O 6
ES09 (2.0L) In Battery Positive Terminal
T/O7
ES09 (2.4L) Near Battery Positive Terminal 4
NS/GS8W - 95 SPLICE LOCATIONS 8W - 95 - 1

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

ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION
PRESSURE LEAKAGE TEST.............. 8
CYLINDER COMPRESSION PRESSURE TEST . . 7
ENGINE DIAGNOSISÐMECHANICAL......... 12
ENGINE DIAGNOSISÐPERFORMANCE...... 10GENERAL INFORMATION.................. 7
INSPECTION
(ENGINE OIL LEAKS IN GENERAL)......... 8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS..... 7
LASH ADJUSTER (TAPPET)
NOISE DIAGNOSIS...................... 8
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System, for the fuel system diag-
nosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If a change in RPM'S, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
(7) Repeat the previous step for all remaining cyl-
inders.
(8) Compression should not be less than (689kPa)
100 psi and not vary more than 25 percent from cyl-
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
NSENGINE 9 - 7