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1996 Plymouth Voyager CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Plymouth REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1996 Plymouth Voyager car and truck
repair procedures including Plymouth engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Plymouth Voyager automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Cooling Fans -> Light Trucks & Vans -> Diagnosis & Testing -> Cherokee & Dakota -> Dakota -> Fan Motor -> Fan Motor Circuit -> Using Diagnostic Readout Box (DRB) -> Using Malfunction Indicator Lamp (MIL)
Vehicle: 1996 Plymouth Voyager SE 3.0 V6 GAS
Fan Motor
Dakota
Disconnect wire connector from fan motor terminal, Fig. , then connect a 14 gauge jumper wire from battery to fan motor terminal. Replace fan motor if it does not operate normally.
Fan Motor Circuit
Cherokee & Dakota
These models are equipped with an engine controller which will detect and store a diagnostic trouble code for the cooling fan system. This information may be accessed by using a DRB diagnostic tool or the Malfunction Indicator Lamp (MIL).
Using Malfunction Indicator Lamp (MIL)
- Obtain MIL d...
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BRAKE SERVICE PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Anti-lock Brakes -> Caravan, Town & Country & Voyager -> Diagnosis & Testing -> 1992 -> 1992-93 -> 1993 -> 1994 -> 1994-95 -> 1995-96 -> 1996 -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Component Testing -> Connector Identification -> Diagnostic Trouble Code Interpretation -> Hydraulic Assembly Internal Leak Inspection -> Intermittent Fault Diagnosis -> Wiring Diagrams
Vehicle: 1996 Plymouth Voyager 2.4 L4 GAS
Accessing Diagnostic Trouble Codes
The diagnostic connector, Figs. and , is located under the lefthand side of the instrument panel. On 1992-94 models, it is a blue 6-way connector; on 1995 models, it is a black 8-way connector. 1996 models utilize a 16-way connector which also serves as a diagnostic link for the PCM and air bag electronic control module. In all cases, a DRB diagnostic scan tool can be linked to this connector to obtain diagnostic trouble codes.
1992-93
- Connect DRB scan tool to diagnostic connector.
- Turn ignition switch to On position. Do not touch keypad durin...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> Caravan, Town & Country & 1984-03 Voyager -> Normal Service -> Severe Service
Vehicle: 1996 Plymouth Voyager SE 3.3 V6 GAS
Normal Servi...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
CV AXLE SHAFT, Replace -> Install -> Remove
Vehicle: 1996 Plymouth Voyager SE 2.4 L4 GAS
Remove
- Remove cotter pin, nut lock, and spring washer from end of outer CV joint stub axle.
- Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with brakes applied. Front hub and driveshaft are splined together and retained by hub nut.
- Raise vehicle on jack stands or centered on a frame contact type hoist.
- Remove front tire and wheel assembly from hub.
- Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts.
- Remove disc brake caliper assembly from steering knuckle. Caliper is removed by f...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Alternator, Replace
Vehicle: 1996 Plymouth Voyager 2.4 L4 GAS
- Disconnect battery ground cable.
- Remove alternator drive belt.
- Disconnect alternator electrical connectors, then remove upper mounting bolt.
- Remove lower mounting bolt, then alternat...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 1996 Plymouth Voyager SE 2.4 L4 GAS
This Emission Maintenance Reminder System (Maintenance Required Lamp) is incorporated into the engine controller. The controller stores vehicle mileage into its memory every eight miles, then at 60,000, 82,500 or 120,000 miles it will light the EMR (Maintenance Required) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following components must be replaced and the EMR lamp reset:
- At 60,00 miles, proceed as follows:
- Replace EGR valve.
- Clean EGR passage.
- Replace PCV valve.
- At 82,500 miles, replace oxygen sensor.
- At 120,000 miles, proceed as ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1996 Plymouth Voyager 3.0 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Dra...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Plymouth Voyager AUTOMOBILES
Serpentine Drive Belt, Replace -> Air Conditioning -> Alternator and Power Steering
Vehicle: 1996 Plymouth Voyager 3.0 V6 GAS
Alternator and Power Steering
- Disconnect battery ground cable from battery.
- Install breaker bar into 1/2 square opening in tensioner.
- Rotate tensioner counterclockwise to relieve belt tension.
- Remove alternator and power steering drive belt.
- Clean and inspect belt surfaces o...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Plymouth Voyager AUTOMOBILES
Component location diagrams for most 1996 Plymouth Voyager cars and light trucks sold in the U.S. from 1990+.
 Engine Compartment Component Locations Diagram for 1996 Plymouth Voyager 2.4 L4 GASComponents on diagram: |
 Engine Compartment Connector Locations Diagram for 1996 Plymouth Voyager SE 2.4 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1996 Plymouth Voyager AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Plymouth Voyager cars and light trucks sold in the U.S.
 1996 Plymouth Voyager 2.4 L4 GAS Wiring DiagramComponents on diagram: |
 1996 Plymouth Voyager SE 3.3 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Plymouth Voyager AUTOMOBILES
OEM TSB listings for most 1996 Plymouth Voyager cars and light trucks sold in the U.S. from 1985+.
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Document: Exterior Lamp Condensation and Replacement Guidelines Vehicle: 1996 Plymouth Voyager 3.0 V6 GAS Symptoms: |
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Document: Exterior Lamp Condensation and Replacement Guidelines Vehicle: 1996 Plymouth Voyager 3.0 V6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Plymouth Voyager AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Plymouth Voyager cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Plymouth Voyager cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Plymouth Voyager cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Plymouth Voyager cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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