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1991 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
A/C & HEATER SERVICE PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
A/C & Cooling System Maintenance -> DaimlerChrysler Corp. -> 1990-94 Chrysler Town & Country, Dodge Caravan & Mini-Ram Van & Plymouth Voyager
Vehicle: 1991 Plymouth Voyager 2.5 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
DISC BRAKES, CHRYSLER CORP. -> General Information -> TROUBLESHOOTING -> BRAKE RATTLE -> BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING -> CALIPER BRAKE FLUID LEAK -> EXCESSIVE PEDAL EFFORT -> EXCESSIVE PEDAL TRAVEL -> HEAVY BRAKE DRAG -> NO BRAKING EFFECT WHEN PEDAL IS DEPRESSED -> PULL, UNEVEN OR GRABBING BRAKES -> REAR BRAKES LOCKING ON APPLICATION
Vehicle: 1991 Plymouth Voyager SE 2.5 L4 GAS
EXCESSIVE PEDAL TRAVEL
- Worn brake lining.
- Pad knock back after cornering or rough road travel.
- Piston or pad assembly not properly seated or positioned.
- Air leak or insufficient fluid in system or caliper.
- Loose wheel bearing adjustment.
- Damaged or worn caliper piston seal.
- Improper booster pushrod adjustment.
- Pads out of flat more than .005 inch.
- Rear brake automatic adjusters inoperative.
- Improperly ground rear brake shoe and lining assemblies.
BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING
- Excessive lateral runout of rotor.
- Rotor excessively out of parallel.
EXCESSIVE PEDAL EFFORT
- Frozen or seiz...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 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: 1991 Plymouth Voyager SE 3.3 V6 GAS
Normal Servi...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
CV AXLE SHAFT, Replace -> Front -> Install -> Rear -> Remove
Vehicle: 1991 Plymouth Voyager 3.0 V6 GAS
Front
Remove
- Remove cotter pin, locknut and spring washer from wheel hub.
- Loosen hub nut with brakes applied.
- Raise and support vehicle, then remove wheel and tire assembly.
- If removing right driveshaft, speedometer pinion must be removed prior to driveshaft removal.
- For all driveshafts, remove ball joint stud to steering knuckle clamp bolt, then separate ball joint stud from steering knuckle using a suitable pry bar. Use caution not to damage ball joint or CV joint boots.
- Separate outer CV joint splined shaft from hub by holding CV housing while moving knuckle/hub assembly away...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Plymouth Voyager SE 2.5 L4 GAS
- Disconnect battery ground cable.
- Remove alternator drive belt.
- Remove alternator mounting bolts, position alternator to gain access to wire connectors.
- Remove B+ terminal nut, field terminal nuts, ground and harness hold down n...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 1991 Plymouth Voyager LE 3.0 V6 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 1991 Plymouth Voyager AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Plymouth Voyager SE 2.5 L4 GAS
Lower
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to radiator.
- Loosen hose clamp connecting hose to water pump.
- Remove hose from vehicle.
- Reverse procedure to i...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Plymouth Voyager AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Plymouth Voyager SE 3.3 V6 GAS
Do not let tensioner arm snap back to freearm position, sever damage may occur to tensioner. Belt tension is not adjustable. Belt adjustment is maintained by an automatic belt tensioner.
- Disconnect battery gr...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Plymouth Voyager AUTOMOBILES
Component location diagrams for most 1991 Plymouth Voyager cars and light trucks sold in the U.S. from 1990+.
Instrument Panel Splices Locations Diagram for 1991 Plymouth Voyager SE 3.3 V6 GAS Components on diagram: |
Roof Splices Diagram for 1991 Plymouth Voyager LE 3.3 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Plymouth Voyager AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Plymouth Voyager cars and light trucks sold in the U.S.
1991 Plymouth Voyager LE 2.5 L4 GAS Wiring Diagram Components on diagram: |
1991 Plymouth Voyager 2.5 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Plymouth Voyager AUTOMOBILES
OEM TSB listings for most 1991 Plymouth Voyager cars and light trucks sold in the U.S. from 1985+.
Document: CHILD SEAT TETHER ANCHOR INSTALLATION - REV Vehicle: 1991 Plymouth Voyager 2.5 L4 GAS Auto Systems: |
Document: WARRANTY - ELECTRONIC EXCHANGE PROGRAM CHANGES - REVISED Vehicle: 1991 Plymouth Voyager 2.5 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Plymouth Voyager AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 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 1991 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 1991 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 1991 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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