1996 CHRYSLER VOYAGER jump cable

JUMP STARTING, HOISTING AND TOWING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS............ 9JUMP STARTING PROCEDURE.............. 7
TOWING RECOMMENDATIONS.............. 8
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. 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 BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, placethe automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
NSLUBRICATION AND MAINTENANCE 0 - 7

JUMP STARTING, HOISTING AND TOWING
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS............. 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 1) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
Fig. 1 Recommended Towing Devices
NS/GSLUBRICATION AND MAINTENANCE 0 - 5

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

HORNS
CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1
DIAGNOSIS AND TESTING
HORN RELAY........................... 1
HORN SYSTEM.......................... 3
HORN SYSTEM TEST..................... 3HORN................................. 1
HORNS SOUND CONTINUOUSLY............ 3
HORNS WILL NOT SOUND................ 2
REMOVAL AND INSTALLATION
HORN SWITCH.......................... 4
HORNS................................ 4
DESCRIPTION AND OPERATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and Body Control Module
(Fig. 1). The horn switch is a membrane switch
located in the airbag cover. The horns are located for-
ward of the left front wheel behind the bumper fas-
cia. The horn relay plugs into the junction block. For
circuit information and component locations refer to
Group 8W, Wiring Diagrams.
DIAGNOSIS AND TESTING
HORN
(1) Disconnect wire connector at horn.
(2) Using a voltmeter, connect one lead to ground
terminal and the other lead to the positive wire ter-
minal (Fig. 3).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer to Horn Will Not Sound. If
voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
ity to ground.
(6) If no ground repair as necessary.
(7) If wires test OK and horn does not sound,
replace horn.
HORN RELAY
(1) Remove horn relay.
(2) Using ohmmeter, test between relay connector
terminals 85 to 86 for 70 to 75 ohms resistance (Fig.
2). If resistance not OK, replace relay.
(3) Test for continuity between ground and termi-
nal 85 of horn relay.
(a) When the horn switch is not depressed, no
continuity should be present.
(b) Continuity to ground when horn switch is
depressed.
(c) If continuity is not correct repair horn
switch or wiring as necessary, refer to Group 8W,
Wiring Diagrams Group 8M Restraint System for
Driver's Airbag Module removal procedures.
(4) Using voltmeter, test voltage at:
(a) Terminals 30 and 86 of the horn relay to
body ground.
(b) If NO voltage check fuse 7 of the BCM.
(c) If incorrect voltage repair as necessary. Refer
to Group 8W, Wiring Diagrams.
(5) Insert a jumper wire between terminal 30 and
87 of the power distribution center.
(a) If horn sounds replace relay.
Fig. 1 Horn System
NSHORNS 8G - 1

SERVO VACUUM TEST
(1) Turn ignition switch to the ON position with-
out starting engine. Activate speed control ON
switch.
(2) Disconnect the four-way electrical connector
and the vacuum harness at the servo (Fig. 3).
(3) Connect a jumper wire from Pin 3 of the servo
to Pin 3 of the wire connector.
(4) Ground Pins 2 and 4 in the servo. Do not con-
nect pin 1.
(5) Connect a hand held vacuum pump to the vac-
uum nipple and apply 10 - 15 inches of vacuum.
(6) If servo pulls cable, replace servo.
(7) Ground Pin 1 on servo.
(8) Check that the throttle cable pulls in and holds
as long as the vacuum pump is connected. After one
minute, check if cable is still holding. If cable does
not hold replace the servo.
(9) Disconnect jumper from pin 3. Cable should
return to rest position. If not, replace servo.
(10) Connect 4 way electrical connector and vac-
uum harness to servo.
SPEED CONTROL SWITCH TEST
Refer to the appropriate Powertrain Diagnostic
Manual for switch test valves.
STOP LAMP SWITCH TEST
(1) Remove the stop lamp switch refer to Stop
Switch Removal/Installation in this section. Discon-
nect connector from stop lamp switch (Fig. 4). Using
an ohmmeter, switch continuity may be checked as
follows:
(2) With switch plunger released, there should be
continuity between Pin 5 and Pin 6.(3) With switch plunger depressed, there should be
continuity:
²Between Pin 1 and Pin 2.
²Between Pin 3 and Pin 4.
(4) If the above results are not obtained, the stop
lamp switch is defective or out of adjustment.
(5) Stop lamp switch adjustment is detailed in
Group 5, Brakes.
ELECTRICAL TESTS AT POWERTRAIN CONTROL
MODULE
(1) Unplug the GRAY 40-way connector from the
Powertrain Control Module (PCM), (Fig. 5).
(2) Remove both steering wheel speed control
switches and disconnect the wire connectors.
Fig. 3 Servo Harness Connector
Fig. 4 Stop Lamp Wiring
Fig. 5 Powertrain Control Module Location
8H - 6 VEHICLE SPEED CONTROL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove protective cap from fuel pressure test
port on fuel rail (Fig. 9) or (Fig. 10).
(4) Place open end of fuel pressure release hose,
tool number C-4799-1, into an approved gasoline con-
tainer. Connect other end of hose C-4799-1 to fuel
pressure test port (Fig. 11). Fuel pressure will bleed
off through the hose into the gasoline container. Fuel
gauge C-4799-B contains hose C-4799-1.
(5)Replace Pressure test port cap when fin-
ished doing pressure test.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE
(1) Remove the Fuel Pump relay from the Power
Distribution Center (PDC). For location of the relay,
refer to the label on the underside of the PDC cover.
(2) Start and run engine it stalls.
(3) Attemp restarting engine until it will no longer
run.(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unplug connector from any injector.
(6) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(7) Connect the other end of the jumper wire to
the positive side of the battery.
(8) Connect one end of a second jumper wire to the
remaining injector terminal.
CAUTION: Supplying power to an injector for more
than 4 seconds will permantely damage the injector.
Do not leave the injector connected to power for
more than 4 seconds.
Fig. 9 Fuel Pressure Test PortÐ2.4L
Fig. 10 Fuel Pressure Test PortÐ3.3/3.8L
Fig. 11 Releasing Fuel Pressure
NSFUEL SYSTEM 14 - 11

(9) Momentarily touch the other end of this
jumper wire to the negative terminal of the battery
for no more than 4 seconds.
(10) Place a rag or towel below the fuel line at the
quick connect to the rail.
(11) Disconnect the quick connect fitting to the
rail. Refer to Quick-Connect Fittings in this section.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in the PCM memory due to the
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to group 25, On-Board
Diagnostics.
HOSES AND CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 12).Do not rely upon the
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
FUEL FILTER
The fuel filter mounts to the top of the fuel tank.
The inlet and outlet tubes are permanently attached
to the filter (Fig. 13).
Fig. 12 Plastic Quick-Connect Fitting/Fuel Tube
Connection
14 - 12 FUEL SYSTEMNS
SERVICE PROCEDURES (Continued)