1996 CHRYSLER VOYAGER hood release

ABS DIAGNOSTICS MANUAL
Detailed procedures for diagnosing specific ABS
conditions are covered in the diagnostics manual cov-
ering the ITT Teves Mark 20 ABS system. The fol-
lowing information is presented to give the
technician a general background on the diagnostic
capabilities of the ITT Teves Mark 20 ABS system.
Please refer to the above mentioned manual for any
further electronic diagnostics and service procedures
that are required.
DRB DIAGNOSTIC SCAN TOOL USAGE
The diagnostics of the ITT Teves Mark 20 ABS sys-
tem is performed using the DRB scan tool. Refer to
the diagnostics manual covering the ITT Teves Mark
20 ABS system for the required diagnostics and test-
ing procedures and the DRB operators manual for its
proper operational information.
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR
On this vehicle, the diagnostic connector used for
the diagnosis of the ITT Teves Mark 20 ABS system
is located under the lower steering column cover, to
the left side of the steering column, just below the
hood release lever (Fig. 17). The ITT Teves Mark 20
ABS system uses the ISO 9141-K connector which is
shared by other vehicle diagnostic systems such asthe powertrain control module and air bag electronic
control module.ABS SYSTEM SELF DIAGNOSTICS
The ITT Teves Mark 20 ABS system is equipped
with a self diagnostic capability which may be used
to assist in the isolation of ABS faults. The features
of the self diagnostics system are described below.
Fig. 16 Traction Control Hydraulic Circuit
Fig. 17 Diagnostic Scan Tool Data Link Connector
5 - 96 BRAKESNS
DIAGNOSIS AND TESTING (Continued)

BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
SAFETY PRECAUTIONS AND WARNINGS..... 1
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)........ 1
CHARGING TIME REQUIRED............... 2
DIAGNOSIS AND TESTING
BATTERY BUILT-IN TEST INDICATOR........ 2
BATTERY IGNITION OFF DRAW (IOD)........ 3
BATTERY LOAD TEST..................... 4
BATTERY OPEN CIRCUIT VOLTAGE TEST..... 6SERVICE PROCEDURES
BATTERY CHARGING..................... 6
CHARGING COMPLETELY DISCHARGED
BATTERY............................. 7
VISUAL INSPECTION..................... 7
REMOVAL AND INSTALLATION
BATTERY TRAY.......................... 9
BATTERY............................... 8
SPECIFICATIONS
BATTERY SPECIFICATIONS............... 10
TORQUE.............................. 10
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabilizes, and delivers electri-
cal current to operate various electrical systems in
the vehicle. The determination of whether a battery
is good or bad is made by its ability to accept a
charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid
in the electrolyte is measured as specific gravity
using a hydrometer. The original equipment (OE)
battery is equipped with a hydrometer (test indica-
tor) built into the battery cover. The specific gravity
indicates the battery's state-of-charge. The OE bat-
tery is sealed and water cannot be added.
The battery is vented to release gases that are cre-
ated when the battery is being charged and dis-
charged. The battery top, posts, and terminals should
be cleaned when other under hood maintenance is
performed.
When the electrolyte level is below the top of the
plates, Clear in the test Indicator, the battery must
be replaced. The battery must be completely charged,
and the battery top, posts, and cable clamps must be
cleaned before diagnostic procedures are performed.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE. DO NOT USE
OPEN FLAME NEAR BATTERY. REMOVE METALLIC
JEWELRY WORN ON HANDS OR WRISTS TO AVOID
INJURY BY ACCIDENTAL ARCING OF BATTERY
CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING DEVICE,
DO NOT ALLOW THE DISABLED VEHICLE'S BAT-
TERY TO EXCEED 16 VOLTS. PERSONAL INJURY
OR DAMAGE TO ELECTRICAL SYSTEM CAN
RESULT.
TO PROTECT THE HANDS FROM BATTERY ACID, A
SUITABLE PAIR OF HEAVY DUTY RUBBER
GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD
BE WORN WHEN REMOVING OR SERVICING A
BATTERY. SAFETY GLASSES ALSO SHOULD BE
WORN.
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)
A completely normal vehicle will have a small
amount of current drain on the battery with the key
out of the ignition. It can range from 5 to 25 milli-
amperes after all the modules time out. If a vehicle
will not be operated for approximately a 20 days, the
IOD fuse should be pulled to eliminate the vehicle
electrical drain on the battery. The IOD fuse is
NSBATTERY 8A - 1

BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
SAFETY PRECAUTIONS AND WARNINGS.... 1
DESCRIPTION AND OPERATION
BATTERY IGNITION OFF DRAW (IOD)....... 2
CHARGING TIME REQUIRED.............. 2
DIAGNOSIS AND TESTING
BATTERY DISCHARGING................. 3
BATTERY IGNITION OFF DRAW............ 3
BATTERY LOAD TEST................... 5
BATTERY OPEN CIRCUIT VOLTAGE TEST.... 6SERVICE PROCEDURES
BATTERY CHARGING.................... 6
CHARGING COMPLETELY DISCHARGED
BATTERY............................ 7
VISUAL INSPECTION.................... 7
REMOVAL AND INSTALLATION
BATTERY............................. 8
BATTERY TRAY........................ 9
SPECIFICATIONS
BATTERY SPECIFICATIONS............... 9
TORQUE............................. 10
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabilizes, and delivers electri-
cal current to operate various electrical systems in
the vehicle (Fig. 1). The determination of whether a
battery is good or bad is made by its ability to accept
a charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid
in the electrolyte is measured as specific gravity
using a hydrometer. The specific gravity indicates the
battery's state-of-charge.
The battery is vented to release gases that are cre-
ated when the battery is being charged and dis-
charged.
The battery top, posts, and terminals should be
cleaned when other under hood maintenance is per-
formed.
The battery top, posts, cable clamps must be
cleaned and battery must be completely charged
before diagnostic procedures are performed.
SAFETY PRECAUTIONS AND WARNINGS
WARNING:
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW THE DISABLED VEHI-
CLE'S BATTERY TO EXCEED 16 VOLTS. PER-
SONAL INJURY OR DAMAGE TO ELECTRICAL
SYSTEM CAN RESULT.
TO PROTECT THE HANDS FROM BATTERY
ACID, A SUITABLE PAIR OF HEAVY DUTY RUB-
Fig. 1 Battery Construction
NS/GSBATTERY 8A - 1

CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 7). Refer to the operating instructions
provided with the tester being used.
(2) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location. The 2.5L Diesel Engine, to disable the
engine from starting, disconnect wire connector from
the Fuel Solenoid.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
position or with the clutch pedal depressed and SET
parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
6).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps or the Diesel engine
above 450 amps, check for engine seizing or faulty
starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps or Diesel engine above 500 amps,
the problem is the starter. Replace the starter refer
to starter removal.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testingequipment and connect ASD relay or the Fuel Sole-
noid. Start the vehicle several times to assure the
problem has been corrected.
REMOVAL AND INSTALLATION
STARTERÐ2.4L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 8).
(3) Hoist and support vehicle on safety stands.
(4) Disconnect solenoid wire connector from termi-
nal.
(5) Remove nut holding B+ wire to terminal.
(6) Disconnect solenoid and B+ wires from starter
terminals.
(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 9).
(8) Remove starter.
Fig. 7 Volt-Ampere Tester Connections
Fig. 8 Battery Negative Cable
Fig. 9 Starter±2.4L Engine
NSSTARTER 8B - 5
DIAGNOSIS AND TESTING (Continued)

INSTALLATION
(1) Place starter in position on vehicle.
(2) Install bolts to hold starter to transaxle bell-
housing.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Connect solenoid wire connector onto terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
STARTERÐ3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 8).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding solenoid wire to terminal
(Fig. 10).
(5) Remove nut holding B+ wire to terminal (Fig.
6)
(6) Disconnect solenoid and B+ wires from starter
terminals.
(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 11).
(8) Remove starter.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install bolts to hold starter to transaxle bell-
housing.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Install nut to hold solenoid wire to terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
STARTERÐ3.3/3.8L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 8).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 12).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 13).
(7) Remove starter from bellhousing (Fig. 14).
(8) Separate starter spacer from transaxle bell-
housing.
INSTALLATION
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install bolts to hold starter to transaxle bell-
housing.
Fig. 10 Wire Connectors
Fig. 11 Starter±3.0L Engine
Fig. 12 Wire Connectors
8B - 6 STARTERNS
REMOVAL AND INSTALLATION (Continued)

2.4L ENGINE - With Manual Transaxle
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(4) Disconnect solenoid wire connector from termi-
nal.
(5) Remove nut holding B+ wire to terminal.
(6) Disconnect solenoid and B+ wires from starter
terminals.
(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 3).
(8) Remove starter.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque.(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Connect solenoid wire connector onto terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
2.4L ENGINE - With Automatic Transaxle
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(4) Disconnect solenoid wire connector from termi-
nal.
(5) Remove nut holding B+ wire to terminal.
(6) Disconnect solenoid and B+ wires from starter
terminals.
Fig. 3 Starter - 2.4L Engine with Manual Transaxle
8B - 2 STARTING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 4).
(8) Remove starter.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Connect solenoid wire connector onto terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding solenoid wire to terminal
(Fig. 5).(5) Remove nut holding B+ wire to terminal (Fig.
6)
(6) Disconnect solenoid and B+ wires from starter
terminals.
Fig. 4 Starter - 2.4L Engine with Automatic Transaxle
Fig. 5 Wire Connectors
NS/GSSTARTING SYSTEM 8B - 3
REMOVAL AND INSTALLATION (Continued)

(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 6).
(8) Remove starter.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Install nut to hold solenoid wire to terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
3.3/3.8L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 7).
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing.
(7) Remove starter from bellhousing (Fig. 8).
(8) Separate starter spacer from transaxle bell-
housing.INSTALLATION
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque.
(4) Connect solenoid connector into starter.
(5) Install nut to hold B+ terminal to starter sole-
noid.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
Fig. 6 Starter±3.0L Engine
Fig. 7 Wire Connectors
8B - 4 STARTING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)