Trim levels were carried over from the previous generation. Remove the sound absorbers from the ends of the wiper unit. The end caps must be installed before the seals may be installed. Loosely install the coil and mounting bracket assembly to the intake manifold. It is very important that all valve timing marks align properly, or engine damage will result.
Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Install the exhaust system to the exhaust manifolds. Page 13 Back to Top Fig. The Voyager was on magazine's for 1996 and 1997. Disconnect the negative battery cable.
Be sure the timing mark on the balance shaft sprocket yellow dot lines up with lower nickel plated link on the chain. Install the valve covers and new gaskets. If one or more tests indicate irregular, weak or no spark, refer to the coil test. Tighten the exhaust manifold-to-cylinder head nuts to 17 ft. Tighten all bolts to 25 ft. Only badging and minor cosmetics differentiated the Voyager from its rebadged variant.
The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you are tightening. Disconnect the throttle body linkage and all vacuum hoses to the throttle body. Take time to be sure all timing marks are correctly aligned. Reconnect the negative battery cable. Raise and safely support the vehicle.
Tighten the M6 fasteners to 105 inch lbs. Remove the covering from the intake manifold. Remove the attaching nuts securing the wiper unit to the lower windshield fence. Certified Master Tech is proud to offer service repair manuals for your 1996 Plymouth Voyager - download your manual now! Label and disconnect the spark plug wires from the spark plugs. If you hook up vacuum or fuel lines incorrectly, the vehicle may run poorly, if at all. Remove the intake manifold attaching nuts and washers, and remove the intake manifold.
Remove the crankshaft oil seal from the cover using crankshaft seal removal tool C-4991 or equivalent. Disconnect the coil wires, sending unit wire, heater hoses and bypass hose. If a torque figure is not available, remember that if you are using the right tool to perform the job, you will probably not have to strain yourself to get a fastener tight enough. Start the vehicle several times to assure the problem has been corrected. The bottom of the sensor is posi- tioned next to the drive plate. Remove the rocker arms, rocker shafts and bearing caps as an assembly.
Check all the fuses and fusible links related to the cooling fan circuit. Place a small piece of wood between the piston and caliper fingers. Install the attaching bolts and tighten, in sequence, to 115 inch lbs. If equipped, remove the upper auxiliary transaxle cooler lines from the retaining clips on the cooling fan module shroud. Apply a light coating of clean engine oil to the lip of the new camshaft seal. Remove the vacuum harness connectors from the intake plenum. Start the engine and check for leaks.
Be careful not to damage the crankshaft seal surface of the front timing chain cover. Secure the engine ground straps. Reconnect the throttle body vacuum harness and install the ignition coils. Care must be taken to ensure all valve timing marks align after cylinder head and valvetrain service. Put the tip of each injector into its port and place the fuel rail in position. Install the timing chain cover, cylinder heads and intake manifold. Remove the cooling fan module mounting screws.
Disconnect the starter motor wiring and remove the starter motor. Using a floor jack and a block of wood positioned under the oil pan, raise the engine slightly. Install the right engine and left transaxle mount bolts. The United States has a rich history of car-making dating all the way back to the late 1800s. Label and disconnect the spark plug wires from the spark plugs. Remove the front exhaust manifold-to-cylinder head nuts and remove the exhaust manifold.
If equipped, remove the lower auxiliary transaxle cooler lines from the retaining clips on the cooling fan module shroud. Attach the exhaust pipe to the exhaust manifold and tighten the shoulder bolts to 20 ft. Be sure the wiper unit is installed properly over the weld-studs on the lower windshield fence. If necessary to allow for clearance, the balance shaft may be pushed in slightly. This occurs when a part such as a bolt is screwed into a nut or casting at the wrong angle and forced. A visible worn groove in the roller path or on the cam lobes is cause for replacement.