1996 CHRYSLER VOYAGER lock

three injection pump mounting flanges while
gear is being removed.
(d) Install the drive bolt into the gear puller
(Fig. 43). Tighten the drive bolt to press (remove)
the drive gear from injection pump shaft while
driving injection pump rearward from timing gear
cover mounting studs.
(14) Remove pump from engine.Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJUSTING PUMP TIMING
(1) Clean the mating surfaces of injection pump
and timing gear cover.
(2) Install a new injection pump±to±timing gear
cover gasket.(3) Remove the gear removing bolt (drive bolt)
from gear puller.CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
(4) P
lace the key way on the pump shaft to the 11
o'clock position as viewed from the front of pump.
Install the pump into the rear of timing gear cover
while aligning key way on pump shaft into pump gear.
(5) Install and snug the 3 injection pump mount-
ing nuts. This is not the final tightening sequence.
(6) Remove the special gear puller and adapter
tools from timing gear cover.
(7) Install the injection pump drive gear nut and
washer. Tighten nut to 88 N´m (65 ft. lbs.) torque.
(8) Remove access plug and plug washer at rear of
pump (Fig. 45). Thread special dial indicator adapter
tool VM.1011 (Fig. 46) into this opening. Hand
tighten only.
(9) Attach special dial indicator tool VM.1013 into
the adapter tool (Fig. 46).
(10) Using a socket attached to the end of crank-
shaft, rotate the engine (counterÐclockwise as
viewed from front) until thedial indicator stops mov-
ing. This rotation is about 20É to 30É.
(11) S
et the dial indicator to 0 mm. Be sure the tip of
dial indicator is touching the tip inside the adapter tool.
(12) Very slowly rotate the crankshaft clockwise
until movement on dial indicator needle has stopped.
Do not rotate crankshaft after needle move-
ment has stopped. Engine should be at TDC at
this point
(13) Check the TDC dial indicator for TDC.
Fig. 43 Installing Pump Drive Gear Removal Tools
Fig. 44 Injection Pump Mounting Nuts
Fig. 45 Access Plug at Rear of Pump
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 21
REMOVAL AND INSTALLATION (Continued)

(14) Gauge reading should be at 0.60 mm. If not,
the pump must be rotated for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pumpclockwise(as viewed from
front) until .60 mm is indicated on the dial indica-
tor gauge.
(c) Tighten the three pump mounting nuts to 30
N´m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.60 mm. Loosen pump mounting nuts and
readjust if necessary.
(15) Remove dial indicator and adapter tools.
(16) Install access plug and washer to rear of
injection pump.
(17) Install plug at timing gear cover.
(18) Remove dial indicator from valve stem.
(19) Install valve spring and keepers.
(20) Install rocker arm assembly and tighten nuts.
(21) Install and connect the four high±pressure
fuel lines to the fuel injection pump. Also connect
fuel lines at the fuel injectors. For procedures, refer
to High±Pressure Fuel Lines in this group.
(22) Install electrical connector at engine coolant
temperature sensor.
(23) Connect electrical connector at fuel shutdown
solenoid.(24) Connect the main engine wiring harness to
the glow plugs.
(25) Connect the fuel timing solenoid pigtail har-
ness to the engine wiring harness.
(26) Connect the overflow valve/banjo fitting (fuel
return line assembly). Replace copper gaskets before
installing.
(27) Connect the rubber fuel return and supply
hoses to metal lines at pump. Tighten hose clamps to
2 N´m (20 in. lbs.) torque.
(28) Install generator assembly.
(29) Install engine accessory drive belt. Refer to
Group 7, Cooling System for procedures.
(30) Install negative battery cable to battery.
(31) Start the engine and bring to normal operat-
ing temperature.
(32) Check for fuel leaks.
FUEL INJECTORS
Four fuel injectors are used on each engine. Of these
four, two different types are used. The fuel injector used
on cylinder number one is equipped with a fuel injector
sensor (Fig. 47). The other three fuel injectors are iden-
tical.
Do not place the fuel injector equipped with
the fuel injector sensor into any other location
except the cylinder number one position.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Thoroughly clean the area around the injector
with compressed air.
(3) Remove the fuel drain hoses (tubes) at each
injector (Fig. 48) being serviced. Each of these hoses
is slip±fit to the fitting on injector.
(4) Remove the high±pressure fuel line at injector
being removed. Refer to High±Pressure Fuel Lines in
this group for procedures.
(5) Remove the injector using special socket tool
number VM.1012A. When removing cylinder number
Fig. 46 Installing Dial Indicator and Special Adapter
Tools
Fig. 47 Fuel Injector SensorÐNumber±1 Cylinder
14 - 22 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(4) Raise vehicle on hoist.
(5) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank.
(6) Disconnect fuel supply and return lines from
the steel supply line (Fig. 51).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Slide electrical connector lock to unlock (Fig.
52).
(8) Push down on connector retainer (Fig. 53) and
pull connector off module.
(9) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(10) Lower tank slightly. Carefully remove filler
hose from tank.(11) Lower the fuel tank. Remove clamp and
remove fuel filler tube vent hose. Remove fuel tank
from vehicle.
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect fuel filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Remove transmission jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect module electrical connector. Place
retainer in locked position.
(6) Lubricate the fuel supply and return lines with
clean 30 weight engine oil, install the quick connect
Fuel Tank
Fig. 51 Fuel Tank and Lines
Fig. 52 Fuel Line Retainers and Pump Connector
Lock
Fig. 53 Module Connector Retainer and Lock
14 - 24 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

fuel fitting. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(7) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(8) Fill fuel tank, replace cap, and connect battery
negative cable.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeleddieselsafety container.
(4) Raise vehicle on hoist.
(5) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(6) Clean area around fuel reservoir module and
tank to keep dirt and foreign material out of tank.
(7) Disconnect fuel lines from fuel module by
depressing quick connect retainers with thumb and
fore finger (Fig. 54).
(8) Slide module electrical connector lock to
unlock.
(9) Push down on connector retainer (Fig. 55) and
pull connector off module.
(10) Using Special Tool 6856, remove plastic lock-
nut counterclockwise to release pump module (Fig.
56).
(11) Carefully remove module and O-ring from
tank (Fig. 57).(12) Discard old O-ring.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel reservoir module in tank with
locknut.
(3) Tighten locknut to 58 N´m (43 ft. lbs.).
(4) Connect fuel lines.
(5) Plug in electrical connector. Slide connector
lock into position.
(6) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(7) Lower vehicle on hoist.
(8) Connect negative cable from battery.
(9) Fill fuel tank. Check for leaks.
(10) Install fuel filler cap.
Fig. 54 Fuel Line Retainers and Pump Connector
Lock
Fig. 55 Module Connector Retainer and Lock
Fig. 56 Fuel Reservoir Module Lock Nut Removal
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 25
REMOVAL AND INSTALLATION (Continued)

(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
ACCELERATOR PEDAL
Refer to the Accelerator Pedal for the 2.4/3.0/.3.3/
3.8L engines under Removal and Installation in the
Fuel Delivery section of group 14 for more informa-
tion.
TORQUE SPECIFICATION
DESCRIPTION TORQUE
Accelerator Pedal to
Dash Nuts..............12N´m(105 in. lbs.)
Fuel Pump Module Locknut....58N´m(43ft.lbs.)
Fuel Tank Strap Bolts.........54N´m(40ftlbs.)
Fuel Rail Bolts.............23N´m(195 in. lbs.)
Ignition Coil Mounting Bolts . . . 11 N´m (95 in. lbs.)
Intake Manifold Bolts........11N´m(95in.lbs.)
Throttle Control Shield.......5.6N´m(50in.lbs.)
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 31
REMOVAL AND INSTALLATION (Continued)

The first injector sensor is used only on the fuel
injector for the number±1 cylinder (Fig. 3). It is not
used on the injectors for cylinders number 2, 3, or 4.
FUEL INJECTOR SENSORÐGROUND
Provides a low noise ground for the fuel injector
sensor only.
ENGINE COOLANT TEMPERATURE SENSORÐPCM
INPUT
The 0±5 volt input from this sensor tells the PCM
the temperature of the engine coolant. Based on the
voltage received at the PCM, it will then determine
operation of the fuel timing solenoid, glow plug relay,
electrical vacuum modulator (emission component)
and generator (charging system).
The sensor is located on the side of the #3 cylinder
head near the rear of fuel injection pump (Fig. 4).
ENGINE SPEED SENSORÐPCM INPUT
The engine speed sensor is mounted to the trans-
mission bellhousing at the left/rear side of the engine
block (Fig. 5).
The engine speed sensor produces its own output
signal. If this signal is not received the engine will
not start by the PCM.
The engine speed sensor input is used in conjunc-
tion with the first injector sensor to establish fuel
injection pump timing.
The flywheel has four notches at its outer edge
(Fig. 6). Each notch is spaced equally every 90É. The
notches cause a pulse to be generated when they
pass under the speed sensor (Fig. 6). These pulses
are the input to the PCM. The input from this sensor
determines crankshaft position (in degrees) by moni-
toring the notches.The sensor also generates an rpm signal to the
PCM. This signal is used as an input for the Diesel
relay for control of the generator field, vehicle speed
control, and instrument panel mounted tachometer.
If the engine speed sensor should fail, the system
is unable to compensate for the problem and the car
will stop.
Fig. 3 Fuel Injector Sensor
Fig. 4 Engine Coolant Temperature Sensor Location
Fig. 5 Engine Speed Sensor Location
14 - 46 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
DESCRIPTION AND OPERATION (Continued)

²When the PCM energizes the Diesel PCM and
other relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
TESTING
The following procedure applies to the Diesel PCM
and other relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
(6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
power source.Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wire to
relay terminal 86. This activates the relay. The ohm-meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.
(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the Die-
sel PCM and other relay circuits. Refer to group 8W,
Wiring Diagrams.
BOOST PRESSURE SENSOR
If the boost pressure sensor fails, the PCM records
a DTC into memory and continues to operate the
engine in one of the three ªlimp-inº modes. When the
PCM is operating in this mode, a loss of power will
be present, as if the turbocharger was not operating.
The best method for diagnosing faults with the boost
pressure sensor is with the DRB III 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.
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and its related cir-
cuitry, refer to 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.
DIAGNOSTIC TROUBLE CODES
For a list of Diagnostic Trouble Codes (DTC's),
refer to Group 25, Emission Control System for infor-
mation. See On-Board Diagnostics.
REMOVAL AND INSTALLATION
DIESEL PCM RELAY
The Diesel PCM relay is located in the PDC. For
the location of the relay within the PDC, refer to
label on PDC cover.
A/C CLUTCH RELAY
The A/C clutch relay is located in the PDC. For the
location of the relay within the PDC, refer to label on
PDC cover.
ENGINE SPEED SENSOR
The engine speed sensor is mounted to the trans-
mission bellhousing at the rear of the engine block
(Fig. 18).
REMOVAL
(1) Disconnect the harness (on the sensor) from
the main electrical harness.
Fig. 17 Diesel PCM and Other Relay Terminals
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 53
DIAGNOSIS AND TESTING (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)